Simulation-based design of high performance internal grinding processes
Final Report Abstract
High performance internal traverse grinding using electroplated CBN grinding wheels offers high potential for bore machining of parts made of hardened steel. The process enables the combination of roughing and finishing in a single axial feed stroke at high material removal rates and with low tool wear. However, process control is hard to achieve especially regarding errors in the geometry of the bore caused by the heat induced by the grinding process and by deflections of tool and machine tool. The main focus of the project reported here was on extending a simulation system, which is able to predict the influence of process heat and workpiece clamping on the bore geometry and was developed in the course of the DFG-Schwerpunktprogramm 1480 (Thermal Effects in Complex Machining Processes), with models for process forces, grinding system deflections and tool wear. By combining an empirical compliance model with a surrogate single grain force model, calibrated using FEM, the developed geometric physically based simulation is able to predict the influence of deflections on the geometry of the bore. Using this simulation a novel NC path design was developed and a reduction of the remaining error in the profile along the bore by approximately 50% was achieved in an industrial example process. Furthermore, based on extensive empirical tool wear experiments, a modified grinding wheel was elaborated, which doubled tool life using the same process parameters.
Publications
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Produktionstechnologie im Wandel – neue Anforderungen an die Schleiftechnologie. Konferenzvortrag, Dortmunder Schleifseminar, 29.09. - 30.09.2021, Dortmund
W. Heuer, T. Tsagkir Dereli, F. Hofmann, J. Liedel, S. Woiwode, S. Schindler, N. Schmidt, T. Furlan, A. Menzel & D. Biermann
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Prozessoptimierung für das Innenrundschälschleifen. VDI-Z, 162(03), 25-27.
Holtermann, Raphael; Furlan, Tim; Schmidt, Nils; Dereli, Tsagkir Tountzer; Menzel, Andreas & Biermann, Dirk
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Towards the Prediction of Compliance Influences on Shape Deviations in Internal Traverse Grinding. Lecture Notes in Production Engineering, 304-314. Springer Berlin Heidelberg.
Schmidt, N.; Tsagkir, Dereli T.; Furlan, T.; Holtermann, R.; Biermann, D. & Menzel, A.
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Simulation Based Prediction of Compliance Induced Shape Deviations in Internal Traverse Grinding. Journal of Manufacturing and Materials Processing, 5(2), 60.
Tsagkir, Dereli Tountzer; Schmidt, Nils; Furlan, Tim; Holtermann, Raphael; Biermann, Dirk & Menzel, Andreas
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Effizienzsteigerung durch Schleifen im Hochgeschwindigkeitsbereich Lösungen für die Prozessauslegung, Konferenzvortrag, Fellbacher Schleiftagung, 26 - 27.01.2022, online
D. Biermann, T. Tsagkir Dereli & P. Latta
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On Visualisation of Finite Element Cutting Simulations. Konferenzvortrag, GACM Colloquium on Computational Mechanics 2022, 21.-23.02.2022, Essen.
T. Furlan, J. Stollberg, T. Tsagkir Dereli, N. Schmidt, D. Biermann & A. Menzel
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Qualitäts- und Effizienzsteigerung durch innovative Lösungen im Bereich der Schleiftechnologie, Konferenzvortrag; Grinding Hub Websession 2022, 28.04.2022, online
T. Tsagkir Dereli, T. Furlan, N. Schmidt, P. Latta, A.Menzel & D. Biermann
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Simulationsbasierte Auslegung von Hochleistungs-Innenrundschleifprozessen, Vortrag Postersession Fellbacher Schleiftagung, 26 - 27.01.2022, online
T.Tsagkir Dereli, N. Schmidt & T.Furlan
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Standzeitverdopplung beim Hochgeschwindigkeits-Innenrundschälschleifen mit modifizierten galvanisch gebundenen CBN-Werkzeugen. Diamond Business 3, 40-47 (2022)
T. Tsagkir Dereli, T. Furlan, N. Schmidt, J. Liedel, A. Menzel & D. Biermann
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Application of the Coupled Eulerian Lagrangian method to the prediction of single‐grain cutting forces in grinding. PAMM, 22(1).
Furlan, Tim; Tsagkir, Dereli Tountzer; Schmidt, Nils; Biermann, Dirk & Menzel, Andreas
