Kinematic Simulation for Analyzing and Predicting High-Performance Grinding Processes

In grinding technology, the application of superabrasives and increasing demands for higher productivity and higher quality require an appropriate selection of optimum set-up parameters. Therefore, the development of analytical or empirical models for reliable prediction of machining performance and work results is a key issue. This paper presents a comprehensive concept for process modeling which provides a software tool for analyzing and designing high performance grinding processes, using the method of kinematic simulation. On the basis of synthetic 3D-models describing the macro- and micro-geometry of the grinding wheel and the workpiece, together with mathematical models describing the relative motions and kinematic engagement conditions, grinding processes can be reproduced as the cumulation of multiple grit engagements. The proposed simulation tool allows the generation of optional grinding wheel topographies and the analysis and prediction of the machining performance and work result for different grinding techniques, taking into account thermo-mechanical and dynamic effects in the contact area.