Model-based analysis of the effects of bond properties and thermomechanical influences on the grain-bond interface during grinding with sintered metal bonded tools

• Applicant: Professor Dr.-Ing. Berend Denkena
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: since 2022
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 504889301

As a result of thermomechanical stress in the grinding process, plastic bond deformations occur in the bronze bonding. This has been demonstrated by preliminary work at IFW. These deformations and the influence of the deformations on the resulting grinding wheel topography have not been investigated in sufficient detail. In the present research proposal, the deformation of the bronze bond in the grinding process with CBN is investigated in assistance of simulation models. To ana-lyze the grinding behaviour single grain grinding pins with CBN grains are manufactured and single grain grinding tests are carried out with variable bronze bond specifications, cutting speeds and in-feeds. Forces and temperatures are measured. In parallel, a simulation model of the single grain grinding process is built in which the grain orientation is kept variable and the grain deformation and temperatures are measured by a tribometer and REM. Based on the results of the finite element simulation and measured grinding tool surface profiles, a kinematics simulation is performed using the "IFW CutS" software. This simulation is validated with grinding tests. Through the simulation model and validation, the influence of bond deformation on the resulting surface profile is quantified. The main objective of the planned research project is the knowledge about the influence of bond properties and thermomechanical influences on the grain-bond interface as well as the resulting grinding tool application behaviour.

• DFG Programme: Research Grants