Towards the Prediction of Compliance Influences on Shape Deviations in Internal Traverse Grinding

Simulation Based Prediction of Compliance Induced Shape Deviations in Internal Traverse Grinding

“…The simulation system presented in this work is an extension of the results presented in [35], where a compliance model which was calibrated based on static analogy tests was proposed. Using a kinematic simulation, final workpiece contours were predicted based on process forces recorded in grinding investigations.…”

“…To validate the models and to evaluate the transferability of the proposed methods between different machines and process strategies, the experimental results from the industrial setting presented in [35] are compared to the results of the new simulation system and additional experimental grinding tests. In addition, static compliance tests were performed in the laboratory setting in analogy to [35]. For the sake of clarity and for the reader's convenience, the contents of the previous work are briefly recapitulated in the following sections whenever the same method was applied to the laboratory machine.…”

“…Using two internal cylindrical grinding machines with different workpiece clamping and spindle systems, static analogy investigations were carried out to determine the influence of spindle compliance on grinding results and to model it in a geometric kinematic grinding simulation. One test series took place on an internal cylindrical grinding machine in an industrial environment, in collaboration with Schaeffler Technologies AG & Co. KG (Herzogenaurach, Germany) [35]. Another series of tests was carried out on the internal grinding machine IC 400 by Danobat Overbeck in a laboratory environment for the current work.…”

“…The experimental investigations presented in the following were limited to three relative tool positions due to the required effort. Although the classic Bernoulli beam theory predicts a third order polynomial for the function ̃ for a clamped cantilever beam of constant cross-section loaded by a point force, we restrict the model to the linear ansatz In order to map the deformation of the spindle system, consisting of workpiece spindle and tool spindle, as a function of the acting normal forces, static analogy tests as described in [35] for the industrial setting were performed for the laboratory machine. The cylindrical finishing zone of the grinding tool was moved in 0.5 µm steps in radial direction against the workpiece clamped in the clamping device.…”

“…Various analytical models for the prediction of process forces during grinding were proposed e.g., in [31][32][33][34]. A simplified model for the effective compliance of the grinding machine system, accompanied by a static analogy test for the experimental calibration, has recently been proposed in [35].…”