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Production Engineering

, Volume 9, Issue 4, pp 451–463 | Cite as

Modelling and simulation of Internal Traverse Grinding: bridging meso- and macro-scale simulations

  • Raphael HoltermannEmail author
  • Andreas Menzel
  • Sebastian Schumann
  • Dirk Biermann
  • Tobias Siebrecht
  • Petra Kersting
Computer Aided Engineering

Abstract

In this work, we focus on the computational bridging between the meso- and macro-scale in the context of the hybrid modelling of Internal Traverse Grinding with electro-plated cBN wheels. This grinding process satisfies the manufacturing industry demands for a high rate of material removal along with a high surface quality while minimising the number of manufacturing processes invoked. To overcome the major problem of the present machining process, namely a highly concentrated thermal load which can result in micro-structural damage and dimension errors of the workpiece, a hybrid simulation framework is currently under development. The latter consists of three components. First, a kinematic simulation that models the grinding wheel surface based on experimentally determined measurements is used to calculate the transient penetration history of every grain intersecting with the workpiece. Secondly, an h-adaptive, plane-strain finite element model incorporating elasto-plastic work hardening, thermal softening and ductile damage is used to simulate the proximity of one cBN grain during grinding and to capture the complex thermo-mechanical material response on a meso-scale. For the third component of the framework, the results from the preceding two simulation steps are combined into a macro-scale process model that shall in the future be used to improve manufacturing accuracy and to develop error compensation strategies accordingly. To achieve this objective, a regression analysis scheme is incorporated to approximate the influence of the several cutting mechanisms on the meso-scale and to transfer the homogenisation-based thermo-mechanical results to the macro-scale.

Keywords

Grinding 100Cr6(AISI 52100) cBN Finite element method h-Adaptive remeshing 

Mathematics Subject Classification

74F05 74R99 

Notes

Acknowledgments

Financial support by the Deutsche Forschungsgemeinschaft (DFG) in the context of SPP 1480 (Project IDs: ME 1745/7-3; BI 498/23-3) is gratefully acknowledged.

Conflict of interest

The authors declare that they have no conflict of interest.

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Copyright information

© German Academic Society for Production Engineering (WGP) 2015

Authors and Affiliations

  • Raphael Holtermann
    • 1
    Email author
  • Andreas Menzel
    • 1
    • 3
  • Sebastian Schumann
    • 2
  • Dirk Biermann
    • 2
  • Tobias Siebrecht
    • 2
  • Petra Kersting
    • 2
  1. 1.Institute of MechanicsTU DortmundDortmundGermany
  2. 2.Institute of Machining TechnologyTU DortmundDortmundGermany
  3. 3.Division of Solid MechanicsLund UniversityLundSweden

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