Abstract: The interaction of the machine-process in grinding frequently brings unpredictable results to the quality of the products and processing stability. This paper presents a multi-grains grinding model to simulate the precision grinding process of cemented carbide inserts. The interaction between the grinding process and machine tool is then investigated based on the proposed grinding model. First, the real topography of the grinding wheel is simulated. Based on the assumption of spacing distribution of multi-grains and the virtual grid method, the hexahedron abrasive grains are randomly distributed on the surface of the virtual grinding wheel and the postures of abrasive grains are randomly allocated. Second, the grinding model is built by importing the virtual grinding wheel model into Deform-3D software, and the grinding force values are obtained by simulation. The validity of the proposed grinding model is verified by experiments. Then, the interaction coupling simulation of the machine tool structure and grinding process is built to investigate the interaction mechanism. The simulations reveal that remarkable interactive effects exist between the deformation of the grinding wheel of the machine tool and grinding force. The finite element method (FEM) coupling simulation method proposed in this paper can be used to predict the machine-process interaction.

基于多颗磨粒随机分布的虚拟砂轮建模及机床-工艺交互仿真

[1]Altintas, Y., Brecher, C., Weck, M., et al., 2005. Virtual machine tool. CIRP Annals-Manufacturing Technology, 54(2):115-138.

[2]Anderson, D., Warkentin, A., Bauer, R., 2011. Experimental and numerical investigations of single abrasive-grain cutting. International Journal of Machine Tools and Manufacture, 51(12):898-910.

[3]Aurich, J.C., Kirsch, B., 2012. Kinematic simulation of high-performance grinding for analysis of chip parameters of single grains. CIRP Journal of Manufacturing Science and Technology, 5(3):164-174.

[4]Barge, M., Hamdi, H., Rech, J., et al., 2005. Numerical modelling of orthogonal cutting: influence of numerical parameters. Journal of Materials Processing Technology, 164-165:1148-1153.

[5]Brecher, C., Witt, S., 2006. Simulation of machine process interaction with flexible multi-body simulation. Proceedings of the 9th CIRP International Workshop on Modeling of Machining Operations, Bled, Slovenia, p.171-178.

[6]Brecher, C., Esser, M., Witt, S., 2009. Interaction of manufacturing process and machine tool. CIRP Annals-Manufacturing Technology, 58(2):588-607.

[7]Brinksmeier, E., Aurich, J.C., Govekar, E., et al., 2006. Advances in modeling and simulation of grinding processes. CIRP Annals-Manufacturing Technology, 55(2):667-696.

[8]Chen, X., Rowe, W.B., 1996. Analysis and simulation of the grinding process. Part I: generation of the grinding wheel surface. International Journal of Machine Tools and Manufacture, 36(8):871-882.

[9]Cheng, Z., Xu, J.H., Ding, W.F., et al., 2011. Simulation of chip formation in grinding titanium alloy TC4 with single abrasive grit. Diamond & Abrasive Grains Engineering, 31(2):17-21 (in Chinese).

[10]Doman, D.A., Warkentin, A., Bauer, R., 2009. Finite element modeling approaches in grinding. International Journal of Machine Tools and Manufacture, 49(2):109-116.

[11]Duan, N., Wang, W.S., Yu, Y.Q., et al., 2013. Dynamic simulation of single grain cutting of glass by coupling FEM and SPH. China Mechanical Engineering, 24(20):2716-2721 (in Chinese).

[12]Gong, Y.D., Wang, B., Wang, W.S., 2002. The simulation of grinding wheels and ground surface roughness based on virtual reality technology. Journal of Materials Processing Technology, 129(1-3):123-126.

[13]Hegeman, J.B.J.W., 2000. Fundamentals of Grinding: Surface Conditions of Ground Materials. PhD Thesis, University of Groningen, the Netherlands.

[14]Herzenstiel, P., Robin, C.Y., Ching, S.R., et al., 2007. Interaction of process and machine during high-performance grinding: towards a comprehensive simulation concept. International Journal of Manufacturing Technology and Management, 12(1-3):155-170.

[15]Nguyen, T.A., Butler, D.L., 2005. Simulation of surface grinding process, part 2: interaction of the abrasive grain with the workpiece. International Journal of Machine Tools and Manufacture, 45(11):1329-1336.

[16]Su, Q., Hou, J.M., Zhu, L.D., et al., 2008. Simulation study of single grain cutting based on fluid-solid-interaction method. Journal of System Simulation, 20(10):5250-5253 (in Chinese).

[17]Su, Q., Xu, L., Liu, Y.W., et al., 2013. Numerical simulation of cutting process of CBN grit based on SPH method. China Mechanical Engineering, 24(5):667-671 (in Chinese).

[18]Syoji, K., 2007. Grinding Technology. Mechanical Industry Press, Beijing, China, p.96-97 (in Chinese).

[19]Wang, J.M., Ye, R.Z., Tang, Y.P., et al., 2009. 3D dynamic finite element simulation analysis of single abrasive grain during surface grinding. Diamond & Abrasive Grains Engineering, 173(5):41-45 (in Chinese).

[20]Wang, L.S., Li, G.F., 2002. Modelling and computer simulation for grinding process. China Mechanical Engineering, 13(1):1-4 (in Chinese).

[21]Wang, Y.S., Ding, N., 2005. The grinding force model of cylindrical traverse grinding. Journal of Changchun University, 15(6):1-3 (in Chinese).

[22]Warnecke, G., Barth, C., 1999. Optimization of the dynamic behavior of grinding wheels for grinding of hard and brittle materials using the finite element method. CIRP Annal-Manufacturing Technology, 48(1):261-264.

[23]Weinert, K., Heribert, B., Tim, J., et al., 2007. Simulation based optimization of the NC-shape grinding process with toroid grinding wheels. Production Engineering, 1(3):245-252.

[24]Yan, L., Jiang, F., Rong, Y.M., 2012. Grinding mechanism based on single grain cutting simulation. Journal of Mechanical Engineering, 48(11):172-182 (in Chinese).

[25]Zhang, X.L., Yao, B., Zhao, W.C., et al., 2013. The finite element analysis and optimization for the grinder based on the joint surface. Applied Mechanics and Materials, 281:165-169.

[26]Zheng, M., Gang, T.Q., Yao, B., et al., 2012. Research on the cutting heat and wear of indexable inserts with different transition surfaces. Advanced Materials Research, 468-471:1290-1293.