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Physical Modeling of Process Forces in Grinding

Authors Praveen Sridhar, Daniel Mannherz, Raphael Bilz, Kristin M. de Payrebrune, Mahesh R.G. Prasad, Juan Manuel Rodríguez Prieto

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Author Details

Praveen Sridhar
  • Institute of Computational Physics in Engineering, Technische Universität Kaiserslautern, Germany
Daniel Mannherz
  • Institute of Computational Physics in Engineering, Technische Universität Kaiserslautern, Germany
Raphael Bilz
  • Institute of Computational Physics in Engineering, Technische Universität Kaiserslautern, Germany
Kristin M. de Payrebrune
  • Institute of Computational Physics in Engineering, Technische Universität Kaiserslautern, Germany
Mahesh R.G. Prasad
  • ICAMS, Ruhr-Universität Bochum, Germany
Juan Manuel Rodríguez Prieto
  • Mechanical Engineering Department, Universidad EAFIT, Medellín, Colombia

Funding

This research work was funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) Project ID– 252408385 – IRTG 2057 and Project-ID 172116086 – SFB 926.

Acknowledgements

The authors would like to thank Matthias W. Klein, Marek Smaga and Tilmann Beck from the Institute of Material Sciences and Engineering at Technical Universität Kaiserslautern for their collaboration and for providing us with the experimental data used in section 2.

Cite AsGet BibTex

Praveen Sridhar, Daniel Mannherz, Raphael Bilz, Kristin M. de Payrebrune, Mahesh R.G. Prasad, and Juan Manuel Rodríguez Prieto. Physical Modeling of Process Forces in Grinding. In 2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020). Open Access Series in Informatics (OASIcs), Volume 89, pp. 16:1-16:20, Schloss Dagstuhl – Leibniz-Zentrum für Informatik (2021)
https://doi.org/10.4230/OASIcs.iPMVM.2020.16

Abstract

This paper deals with material removal mechanisms in grinding by considering single grit-workpiece interactions. Individual investigations were performed both experimentally and using finite element simulations. Firstly, a comparison between the Johnson-Cooke material model and a Crystal Plasticity finite element method was performed with the help of micro-indentation experiments. Here the research question was answered if an anisotropic material model better describe the grinding process and process forces compared to an isotropic material model. Secondly, four discretization approaches were employed: pure Lagrangian (LAG), Arbitrary Lagrange Eulerian (ALE), Particle Finite Element Method (PFEM), and Smooth Particle Hydrodynamics (SPH), to simulate a micro-cutting operation of A2024 T351 aluminium. This study aims to compare the conventional approaches (LAG and ALE) to newer approaches (PFEM and SPH). The orthogonal cutting models were benchmarked against a micro-cutting experiment presented in literature, by comparing the obtained cutting and passive forces. The study was then extended to negative rake angles to study the effect on the discretization approaches for grinding. Thirdly, scratch experiments were investigated for a brittle material sodalime glass and A2024 T351 aluminium. Effects of the linear speed of the device, depth of cut, and conical tool angle were analyzed and tendencies are built. Finally, a realistic simulation of the manufacturing process of a grinding wheel was developed, starting with the raw material, compression, sintering, and dressing until the final grinding surface. As a result of the simulations, virtual grinding wheel topographies can be visualized and analyzed with regard to the output variables from grinding wheels such as bonding strength and static grain count. The individual research studies help in understanding the material removal mechanisms in a single grit scratch process as well as in the understanding of the overall grinding wheel topography. This in turn helps in the developing an overall physical force model for scratching/grinding to predict mechanical output parameters and hence reduce the need for experimentation.

Subject Classification

ACM Subject Classification
  • Computing methodologies → Modeling and simulation
Keywords
  • grinding
  • single grit approach
  • finite element method
  • smooth particle hydrodynamics
  • particle finite element method
  • scratch experiments
  • virtual grinding wheel model

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