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Simulation of grinding processes using finite element analysis and geometric simulation of individual grains

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Abstract

The wear-resistance of sheet metal forming tools can be increased by thermally sprayed coatings. However, without further treatment, the high roughness of the coatings leads to poor qualities of the deep drawn sheet surfaces. In order to increase the surface quality of deep drawing tools, grinding on machining centers is a suitable solution. Due to the varying engagement situations of the grinding tools on free-formed surfaces, the process forces vary as well, resulting in inaccuracies of the ground surface shape. The grinding process can be optimized by means of a simulative prediction of the occurring forces. In this paper, a geometric-kinematic simulation coupled with a finite element analysis is presented. Considering the influence of individual grains, an additional approximation to the resulting topography of the ground surface is possible. By using constructive solid geometry and dexel modeling techniques, multiple grains can be simulated with the geometric-kinematic approach simultaneously. The process forces are predicted with the finite element method based on an elasto-plastic material model. Single grain engagement experiments were conducted to validate the simulation results.

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Acknowledgments

This research has been kindly funded by the German Research Foundation (DFG) in research project A5 “Simulation supported NC-shape grinding as a finishing operation of thermally coated deep drawing tools” within the Collaborative Research Center (SFB) 708” 3D-Surface Engineering of Tools for Sheet Metal Forming–Manufacturing, Modeling, Machining”.

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Authors and Affiliations

  1. Institute of Machining Technology, TU Dortmund University, Dortmund, Germany

    T. Siebrecht, D. Biermann, S. Rausch & P. Kersting

  2. Chair for Scientific Computing, TU Dortmund University, Dortmund, Germany

    H. Ludwig, H. Blum & A. Rademacher

Authors
  1. T. Siebrecht
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  2. D. Biermann
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  3. H. Ludwig
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  4. S. Rausch
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  5. P. Kersting
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  6. H. Blum
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  7. A. Rademacher
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Correspondence to T. Siebrecht.

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Siebrecht, T., Biermann, D., Ludwig, H. et al. Simulation of grinding processes using finite element analysis and geometric simulation of individual grains. Prod. Eng. Res. Devel. 8, 345–353 (2014). https://doi.org/10.1007/s11740-013-0524-9

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  • DOI: https://doi.org/10.1007/s11740-013-0524-9

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