Simulation-based tool and process design for microfinishing with metal-bonded honing tools
Final Report Abstract
Based on the results of the previous fundamental research project, investigations into the production of convex contours using microfinishing were carried out and simulation models for prototypical process and tool design were developed within this transfer project. The initial results were transferred prototypically to an industrial application and a new tool concept. For this purpose, the Institute of Machining Technology (ISF) and the Chair of Virtual Machining (VM) carried out the necessary research and developments together with several industry companies, a suitable process chain for profiling, sharpening and running-in of metal-bonded honing tools was defined based on technological investigations. Simultaneously, a geometric physically-based honing simulation was developed with the aim of being able to analyze and systematically adjust different tool configurations, e.g. by varying the grain size or tool shape, and process parameters with regard to the resulting contour of the machined shaft shoulders. In addition to modeling the force control, further models were developed for the detailed representation of the complex process control, which took into account, for example, the orientation of the grain topography in relation to the cutting direction when calculating the individual grain force. The results of the experimental tool and process analysis were used to optimize the simulation parameters and the influence of different tool configurations on the resulting workpiece shape. Based on the project results, the project partners were able to achieve reproducible results for tool conditioning using the novel methods. In addition, a potential to reduce the economic costs of tool development for the project partners in the future through simulation-based tool design was identified.
Link to the final report
https://oa.tib.eu/renate/handle/123456789/18899
Publications
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Potenziale von Schleifprozesssimulationen zur Analyse einzelner Korneingriffe und vollständiger Schleifprozesse. Vortrag: Schweizer Schleifsymposium, Zürich, 06.09.2022 - 07.09.2022.
P. Wiederkehr, A. Grimmert, I. Heining, T. Siebrecht & F. Wöste
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Modellierung und Simulation weg- und kraftgeregelter Schleifprozesse. Vortrag: Schleiftagung, Fellbach, 25.01.2023 - 26.01.2023.
P. Wiederkehr, T. Siebrecht, F. Finkeldey, A. Grimmert, I. Heining & F. Wöste
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Potentials of grinding process simulations for the analysis of individual grain engagement and complete grinding processes. Frontiers in Manufacturing Technology, 2.
Wiederkehr, Petra; Grimmert, Adina; Heining, Ines; Siebrecht, Tobias & Wöste, Florian
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Werkzeug-Einlaufverhalten beim Microfinishen/Analysis of the running-in behavior of metal-bonded diamond finishing tools – Tool run-in behavior during microfinishing. wt Werkstattstechnik online, 113(11-12), 482-488.
Tilger, Meik & Biermann, Dirk
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Aktuelle Erkenntnisse zu Microfinishing und zur Innenrundbearbeitung. Vortrag: Schleiftagung, Fellbach, 31.01.2024 - 01.02.2024.
D. Biermann, T. T. Dereli, M. Tilger, N. Schmidt & I. Heining
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Geometric physically-based simulation of microfinishing: tool design impact on workpiece shape. Production Engineering, 19(2), 275-281.
Siebrecht, Tobias; Bergmann, Jim A.; Heining, Ines; Tilger, Meik; Biermann, Dirk & Wiederkehr, Petra
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Simulation of process forces and topographical characteristics of single grains in microfinishing processes. Production Engineering, 18(6), 975-982.
Heining, Ines; Bergmann, Jim A.; Tilger, Meik; Biermann, Dirk & Wiederkehr, Petra
