Numerical Simulation of a Grinding Process for the Spatial Work-pieces: Modeling of Grinding Forces and System Dynamics

Abstract

The paper describes a computation-experimental technique to determine model coefficients of grinding forces using a Nelder-Mead algorithm. As an error function, the paper offers a deviation measure of calculating and experimental grinding forces averaged for a single-pass of the grinding wheel. As an example of cutting forces model coefficients calculation for linear model, in which the grinding forces depend on uncut chip thickness is analyzed. The coefficients vary on abrasive grain geometric parameters and are determined applying the authors-developed method based on Nelder-Mead technique. The measured forces while plane grinding of test work-piece are used to determine the coefficients. Model coefficients are identified if compare the measured data with the results of modeling for grinding by tool with the uniformly distributed abrasive grains with the triangular shape of cutting edge.Grinding dynamics simulation applying the determined coefficients was carried out for the processing of cantilever plane work-piece as a test example. The work-piece was processed by grinding wheel transverse passages made at different distances from the fixation. A selfoscillating process accompanied by vibration of high level was observed for some selected technological parameters of grinding. The simulation has shown qualitative and quantitative compliance with the experiment. It was shown that the intensity of the self-oscillating process arising during the processing depends on the work-piece rigidity and cutting conditions. The results of modeling can be applied in practice in developing the technology process of grinding the spatial work-pieces.

Keywords

• grinding
• forces
• vibrations
• surface model
• geometry simulation algorithm