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Modelling and simulation of Internal Traverse Grinding: bridging meso- and macro-scale simulations

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Abstract

In this work, we focus on the computational bridging between the meso- and macro-scale in the context of the hybrid modelling of Internal Traverse Grinding with electro-plated cBN wheels. This grinding process satisfies the manufacturing industry demands for a high rate of material removal along with a high surface quality while minimising the number of manufacturing processes invoked. To overcome the major problem of the present machining process, namely a highly concentrated thermal load which can result in micro-structural damage and dimension errors of the workpiece, a hybrid simulation framework is currently under development. The latter consists of three components. First, a kinematic simulation that models the grinding wheel surface based on experimentally determined measurements is used to calculate the transient penetration history of every grain intersecting with the workpiece. Secondly, an h-adaptive, plane-strain finite element model incorporating elasto-plastic work hardening, thermal softening and ductile damage is used to simulate the proximity of one cBN grain during grinding and to capture the complex thermo-mechanical material response on a meso-scale. For the third component of the framework, the results from the preceding two simulation steps are combined into a macro-scale process model that shall in the future be used to improve manufacturing accuracy and to develop error compensation strategies accordingly. To achieve this objective, a regression analysis scheme is incorporated to approximate the influence of the several cutting mechanisms on the meso-scale and to transfer the homogenisation-based thermo-mechanical results to the macro-scale.

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Acknowledgments

Financial support by the Deutsche Forschungsgemeinschaft (DFG) in the context of SPP 1480 (Project IDs: ME 1745/7-3; BI 498/23-3) is gratefully acknowledged.

Conflict of interest

The authors declare that they have no conflict of interest.

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Authors and Affiliations

  1. Institute of Mechanics, TU Dortmund, Leonhard-Euler-Straße 5, 44227, Dortmund, Germany

    Raphael Holtermann & Andreas Menzel

  2. Institute of Machining Technology, TU Dortmund, Baroper Straße 303, 44227, Dortmund, Germany

    Sebastian Schumann, Dirk Biermann, Tobias Siebrecht & Petra Kersting

  3. Division of Solid Mechanics, Lund University, P.O. Box 118, 22100, Lund, Sweden

    Andreas Menzel

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  1. Raphael Holtermann
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Correspondence to Raphael Holtermann.

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Holtermann, R., Menzel, A., Schumann, S. et al. Modelling and simulation of Internal Traverse Grinding: bridging meso- and macro-scale simulations. Prod. Eng. Res. Devel. 9, 451–463 (2015). https://doi.org/10.1007/s11740-015-0613-z

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  • DOI: https://doi.org/10.1007/s11740-015-0613-z

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