Grinding simulation by technologically enhanced and geometrically optimized multi-dexel models
Mohn, T.1, a; Rausch, S.1, b; Biermann, D.1, c
- 1)
- Institut für Spanende Fertigung, Technische Universität Dortmund, Baroper Str. 301, 44227 Dortmund
a) mohn@isf.de; b) rausch@isf.de; c) biermann@isf.de
Kurzfassung
Introduction
Grinding is one of the most common manufacturing processes for surface finishing and precision machining. To ensure appropriate process results concerning shape accuracy, thermal damage and surface quality, various simulation models for grinding have been developed. In [1] a geometric-kinematical approach to simulate grinding processes has been explained. This paper will describe the progress in the development of this grinding simulation. A special focus will be the implementation of empirical technological models that allow the enhancement of the geometric-kinematical model to analyze technological aspects for various grinding processes. The optimized workpiece representation for these simulations can be achieved by the automated adaption to the workpiece geometry during the preprocessing.
Methods
The geometric-kinematical simulation described in this paper is based on a multi dexel model that allows an optimized representation of the workpieces free arrangement and alignment of the single nailboards [1]. Therefore a special pre-processor has been developed at the Institute of Machining Technology at Technische Universität Dortmund. This software tool allows the import of CAD data into the simulation and automatically analyzes the geometrical characteristics of the workpiece. The segmentation, arrangement and alignment of the nailboards can be set with respect to these characteristics, such as normal vectors and local geometrical complexity of the surface. The options for creating the models by the pre-processor include the use of the different kinds of nailboards, regular and hierarchical segmentations of the workpiece and the creation of global models such as simple nailboards and nailblock models.
Experimental data for face grinding and NC shape grinding of X210Cr12 has been used to implement empirical force models for the calculation of process forces for these processes. The latest work covers the design and analysis of experiments for face grinding of thermally sprayed coatings on a machining center and the implementation of this data into a force model for the simulation system.
Results
The automatical creation of workpiece models allows an optimal alignment and segmentation of the nailboards for the simulation. Depending on the focus of the simulation, such as global or local machining of the workpiece, various models can be created to meet the geometrical demands for the technological analysis of the processes. In addition to the connection to FEA software various empirical models to calculate process forces can easily be implemented into the system.
References
- [1]
- Biermann, D.; Mohn, T.: A Geometric-Kinematical Approach for the Simulation of Complex Grinding ProcessesIn: Proceedings of the 6th CIRP International Conference on Intelligent Computation in Manufacturing Engineering (CIRP ICME ’08), 2008, Naples, Italy, Teti, R. (Hrsg.), ISBN 978–88–900948–7–3, p. 401-408
Schlüsselwörter
Grinding, Simulation, Force Prediction
Veröffentlichung
In: CIRP ICME ’10 - 7th CIRP International Conference on Intelligent Computation in Manufacturing Engineering, 23.6.-25.6. 2010, Capri (Gulf of Naples), Italy, digital veröffentlicht