Simulation-based design of high performance internal grinding processes

基于仿真的高性能内圆磨削工艺设计

• 批准号: 403857741
• 负责人: Professor Dr.-Ing. Dirk Biermann
• 金额: --
• 依托单位: Institut für Spanende Fertigung
• 依托单位国家: 德国
• 项目类别: Research Grants (Transfer Project)
• 财政年份: 2019
• 资助国家: 德国
• 起止时间: 2018-12-31 至 2021-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/403857741?language=en
• 关键词: Simulation; based; design; performance; internal; Simulation; based; design; performance; internal

Due to the long effective contact time of the grinding grains, complex contact conditions and the difficult-to-handle coolant support, the process layout of internal traverse grinding is still challenging. Because of the high chip space and its aggressive topography, electroplated cBN grinding wheels are used to achieve high productivity when machining hardened steels. High-speed-conditions with grinding wheel velocities higher than 80 m/s significantly raise the realised material removal rate. In the fundamental project in the context of the Priority Programme 1480, a holistic simulation framework with three components was established by modelling the thermo-mechanical loads and their effects of the machining errors in different scales. At the mesoscale, a finite element model was used to model the single grain engagement achieving the thermo-mechanical loads. Due to a geometric-physical simulation the grain engagements were estimated according to the topography of the modelled grinding wheel and transformed to the process scale. On this scale, a thermomechanical coupled finite element model – considering the clamping effect, the thermal induced machining error as well as the material removal – was developed. Based on this, compensation strategies were achieved reducing the machining error along the bore by 50 percent. Without regarding the spindle complaints of grinding and workpiece spindle, a relatively high dimension error remains at the discharge area of the workpiece. The objective of the presented knowledge transfer project is the enhancement of the established holistic simulation framework due to all necessary modelling aspects to generate a prototypical solution for the industrial environment. In the focus are the implementation of the spindle complaints and the grain related wear in the different components of the simulation framework of internal traverse grinding. Due to the close cooperation with industrial application partners, Schaeffler Technologies and August Rüggeberg, the relevant industrials requirements to a simulation based layout of grinding tools and processes are defined. The usage of the holistic simulation framework secures the optimal design of the grinding wheels as well as the generation of the compensation NC-path to reduce the dimensional and form machining errors. Therefore, the application suitability test can be proven to conduct simulation based wear investigations and process ramp-ups provoked by changing the process boundary conditions prior to the process application.

由于研磨谷物的有效接触时间很长，复杂的接触条件和难以处理的冷却液支撑，因此内部遍历研磨的过程布局仍然受到挑战。由于芯片空间高及其侵略性地形，因此电镀式CBN研磨轮用于加工硬化钢时的生产率高。高速公路速度高于80 m/s的高速条件显着提高了实现的材料去除速率。在优先计划1480的背景下的基本项目中，通过建模机械载荷及其在不同尺度中的加工误差的效果来建立一个具有三个组件的整体模拟框架。在中尺度上，使用有限元模型来建模实现热机械载荷的单晶粒参与度。由于几何形态模拟，根据建模的磨轮的地形估算了晶粒的接触，并转换为过程量表。在此规模上，开发了一个热机械耦合有限元模型 - 考虑到夹紧效果，热诱导的加工误差以及材料去除。基于此，实现了补偿策略，将沿孔的加工误差降低了50％。如果没有关于磨削和工件主轴的主轴投诉，则在工件的放电区域仍然存在相对高的尺寸误差。提出的知识转移项目的目的是增强既定的整体模拟框架，这是由于所有必要的建模方面以生成针对工业环境的原型解决方案。重点是实施主轴投诉和与内部遍历磨削框架不同组件中的谷物相关磨损。由于与工业应用合作伙伴，Schaeffler Technologies和AugustRüggeberg的密切合作，定义了基于模拟工具和流程的基于模拟的布局的相关工业要求。整体模拟框架的使用可确保磨轮的最佳设计以及赔偿NC路径的生成，以减少尺寸和形成加工误差。因此，可以证明应用适用性测试可以进行基于模拟的磨损调查，并通过在过程应用程序之前改变过程边界条件引起的过程提升。