An efficient method for solving the Signorini problem in the simulation of free-form surfaces produced by belt grinding

Zhang, Xiang; Kuhlenkoetter, Bernd; Kneupner, Klaus

doi:10.1016/j.ijmachtools.2004.10.006

Cited by 82 publications

(40 citation statements)

References 5 publications

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“…The grinding belt is formed of abrasives coated on a backing material and fastened around at least two rotating polymer contact wheels, which make it a compliant tool, as shown in Figure 1. The soft contact polymer wheel enables this machining process to be appropriate to machine free-form surfaces due to its versatility, efficiency, and ability to machine workpieces of intricate shapes and geometry [1]. Understanding of such a process is one of the most delicate problems in the industry due to the high complexity and nonlinearity.…”

Section: Introductionmentioning

confidence: 99%

“…Jourani et al [2] have presented a three-dimensional numerical model, which could determine pressure distribution along with the distribution of real contact to study the contact between the belt constituted by abrasive grains and the surface to understand the material removal mechanism. Zhang et al [1] have stated that force distribution in the contact area between the workpiece and the elastic contact wheel determines the ratio of material removal in the belt grinding process. Ren et al [3,4] developed a local process model to predict the material removal rate before machining, making it suiT for the robot programmer to optimize the tool path based on simulation results.…”

Section: Introductionmentioning

confidence: 99%

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Predictive Modelling and Analysis of Process Parameters on Material Removal Characteristics in Abrasive Belt Grinding Process

et al. 2017

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Abstract:The surface finishing and stock removal of complicated geometries is the principal objective for grinding with compliant abrasive tools. To understand and achieve optimum material removal in a tertiary finishing process such as Abrasive Belt Grinding, it is essential to look in more detail at the process parameters/variables that affect the stock removal rate. The process variables involved in a belt grinding process include the grit and abrasive type of grinding belt, belt speed, contact wheel hardness, serration, and grinding force. Changing these process variables will affect the performance of the process. The literature survey on belt grinding shows certain limited understanding of material removal on the process variables. Experimental trials were conducted based on the Taguchi Method to evaluate the influence of individual and interactive process variables. Analysis of variance (ANOVA) was employed to investigate the belt grinding characteristics on material removal. This research work describes a systematic approach to optimise process parameters to achieve the desired stock removal in a compliant Abrasive Belt Grinding process. Experimental study showed that the removed material from a surface due to the belt grinding process has a non-linear relationship with the process variables. In this paper, the Adaptive Neuro-Fuzzy Inference System (ANFIS) model is used to determine material removal. Compared with the experimental results, the model accurately predicts the stock removal. With further verification of the empirical model, a better understanding of the grinding parameters involved in material removal, particularly the influence of the individual process variables and their interaction, can be obtained.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Predictive Modelling and Analysis of Process Parameters on Material Removal Characteristics in Abrasive Belt Grinding Process

et al. 2017

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“…GBM 公司铣磨车和中车北京二七轨道交通装备有限责任公司钢轨铣磨车等。目前，国内外对具有特殊工况的钢轨砂带打磨基础理论尤其是因柔性带来的复杂接触机理研究仍十分缺乏，相关研究更多是体现在普通砂带磨削中，较难以支撑钢轨砂带打磨技术的实际工程应用和进一步推广。ZHANG 等 [6][7] 和 REN 等 [8][9] 将接触轮和工件接触关系视为 Signorini 接触问题，基于有限元、神经网络和向量回归等理论，研究了机器人砂带磨削作业过程。刘斐等 [10] 则采用弹性接触力学平面问题的复变函数解法，研究了机器人砂带磨削中砂带张紧对接触轮变形和磨削深度的影响，得到了接触轮的变形分布规律。KHELLOUKI 等 [11][12] 研究了开式砂带磨削中不同硬度接触轮与圆柱工件对滚时的接触弧长，并建立了用于定性分析的接触模型。黄云等 [13] 较为系统的讨论了接触轮弹性变形对砂带磨削的作用机理，着重分析了平面磨削中不同硬度接触轮磨削时的接触长度、有效磨粒数量以及磨粒分布情况。吴昌林等 [14] 、赵燕涛 [15] 及 WANG 等 [16] 利用弹性 Hertz 接触理论建立了叶片砂带磨削过程中砂带与工件曲面的接触模型。针对钢轨砂带打磨，王荣全 [17] …”

Section: 外研究人员的广泛关注，并已经出现了相关装备产品，主要有瑞士公铁两用钢轨砂带打磨车、德国unclassified

Research on Time-varying Contact Behavior and Simulation for Waved Rail Surface Grinding by Abrasive Belt

Fan¹

2018

JME

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Abstract：Due to the complex and varied load impact, the longitudinal rail surface tends to form the wavy irregularity with certain length and amplitude, resulting that the equivalent curvature of rail surface and normal contact stress of the contact area in the process of grinding operation change dynamically. For this purpose, the basic contact characteristic for the waved rail surface grinding by abrasive belt is analyzed. Based on the Hertz contact theory, the macro time-varying contact theory model involved with time, grinding pressure, feed speed, diameter and rubber layer thickness of contact wheel is built, by which the more practical contact area form and stress distribution at any time are revealed. The theory and finite element simulation comparison analysis for the three typical different moments (close to the peak of wave, the trough of wave and the horizontal position respectively) is implemented.Results show that the theoretical calculation data and the simulation data agree well, which verifies correctness and validity of the proposed theory model.

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“…18 The calculation of the elastic deformation can be transformed into a Signorini problem, a contact problem between an elastic body and a rigid body, which is illustrated by Figure 3. 18,19 Here, the classical theoretical model of strain-stress as well as the energy minimization principle which defines the way how a constrained object deforms with the effect of external forces is applied to solve the problem.…”

Section: The Deformation Models Of the Blades And Grinding Toolmentioning

confidence: 99%

Modeling of the working accuracy for robotic belt grinding system for turbine blades

Zhang

et al. 2017

Advances in Mechanical Engineering

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This article presents a calibration model for the whole grinding system to enhance its accuracy, because of the problem of low accuracy of the robotic belt grinding system which is due to the low absolute positioning accuracy of the robot as well as the deformations of the turbine blades and grinding tool under the grinding force. First, the transition matrix of system working accuracy was established and the corresponding evaluation criterion was put forward for the systemic features. Then the deformation of the turbine blades and grinding tool were analyzed and modeled, respectively, and the model of the absolute positioning accuracy of the robot was established based on the geometrical error as well as the compliance error. Finally, based on the models above, a method of error compensation was presented and the flowchart was given. The experiments show that the absolute positioning accuracy of the robot (the average value reduces from 1.186 to 0.154 mm) and the accuracy of the whole grinding system (the average grinding force is 20.4 N which is very close to the predetermined 20 N) have been effectively improved, which prove that the method can help to expand the application scope of the robotic system.

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An efficient method for solving the Signorini problem in the simulation of free-form surfaces produced by belt grinding

Cited by 82 publications

References 5 publications

Predictive Modelling and Analysis of Process Parameters on Material Removal Characteristics in Abrasive Belt Grinding Process

Predictive Modelling and Analysis of Process Parameters on Material Removal Characteristics in Abrasive Belt Grinding Process

Research on Time-varying Contact Behavior and Simulation for Waved Rail Surface Grinding by Abrasive Belt

Modeling of the working accuracy for robotic belt grinding system for turbine blades

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