Grinding is a commonly used finishing process to produce components of desired shape, size and dimensional accuracy. The ultimate goal is to have the maximum workpiece quality, minimum machining time and high economic efficiency by making a selective adaptation of the possible process strategy and chosen parameter selection. The focus of this study arose from a limitation that challenges the grinding industry. The production rate of the ground parts is generally constrained by surface topography and subsurface damage appearing as residual tensile stress, localized burns, and phase transformation induced micro and macro-cracking. This motivates the need for a reliable numerical modelling to simulate the grinding process. The numerical model sought should be able to predict not only the required grinding residual stresses but also the deformation history. The objective of this thesis is to build up a reliable finite element model for grinding-induced residual stress analysis and thus to explore thoroughly the mechanisms in terms of grinding conditions. The variations of the residual stresses and strains at integration points have been examined, and the effects of the friction coefficient (µ), Peclet number (Pe), non dimensional heat transfer coefficient (H) and different magnitudes of input heat flux (Q) on both the microstructure and the residual stress state are analyzed. Finally, based on the new findings in this research, a more comprehensive methodology is suggested for further study.

Orientador: Paulo Roberto de Aguiar / Banca: André Nunes de Souza / Banca: Milton Vieira Júnior / Resumo: Os processos de usinagem são de extrema importância no ramo de indústria metalúrgica, uma vez que quase todas as peças de metais em que se exige uma alta precisão e qualidade de acabamento são produzidas por meio destes processos. Dentre os processos de usinagem destaca-se o processo de retificação, por sua precisão e bom acabamento. É essencial que se conheça bem este processo, já que por ser a última etapa da manufatura, qualquer problema compromente a peça e perde-se o trabalho realizado em todas as etapas anteriores. O presente trabalho visa um estudo comparativo entre a força de corte na retificação medida com um dinamômetro piezelétrico e a potência elétrica do motor que aciona o rebolo. A força de corte é reconhecida como sendo a principal variável de estudos dos processos de usinagem. Tradicionalmente a força de corte é tomada por meio de um dinamômetro, porém este é um dispositivo relativamente caro e de difícil montagem. Usualmente, a força no processo de retificação é tomada por meio de um sensor de corrente, obtendo-se um sinal analógico proporcional à potência consumida pelo motor. Entretanto, esta potência não corresponde à potência mecânica utilizada no corte, e, portanto, imprecisões ocorrem. Neste trabalho, os sinais de potências elétricas e força de corte foram coletados com alta taxa de aquisição, com variações de profundidade de corte e da frequência do motor que aciona o rebolo. Os resultados obtidos mostram que os sinais de potência elétrica do motor que aciona o rebolo sempre foram proporcionais aos sinais de força de corte. Desta forma, é possível o dinamômetro na retificação por sensores de corrente e tensão, com resultados confiáveis. / Abstract: The machining processes are of great importance in the metallurgical industry, since all the metal workpieces demanding high precision and finishing quality are produced through these processes. Among the machining processes the grinding process can be highlighted by its precision and superior finishing. As being the last manufacturing stage, it is very important to have sound knowledge of the grinding process because minor problems can jeopardize the ground part, and then all the previous manufacturing operations will also be lost. This work aims at comparing the cutting force between the one measured through a piezoelectric dynamometer and that one measured by electrical power of the induction motor that drives the grinding wheel. The cutting force is acknowledged as being the most important variable for studying the machining processes. Traditionally, the cutting force is taken by a piezoelectric dynamometer, which is relatively expensive equipment besides requiring a nontrivial setup. Generally, the cutting force in the grinding process is taken by a Hall Effect current sensor to produce an analog signal proportional to the power consumed by the electric motor. However, that power does not correspond to the mechanical power used to grind, and thus imprecision takes place. In this work, the electric power and cutting force were collected by using a high samplinf the rate acquisition for several cutting depths and two electrical frequencies to drives the induction motor. The results showed the electric power signals behaved, in general, proportional to the cutting force measured by the dynamometer. Thus, the Hall Effect curret and voltage sensors can be replaced by dynamometer in the grinding process with reliable results. / Mestre

Made available in DSpace on 2014-06-11T19:24:47Z (GMT). No. of bitstreams: 0 Previous issue date: 2008-01-16Bitstream added on 2014-06-13T20:13:05Z : No. of bitstreams: 1 lanconi_pn_me_bauru.pdf: 2184096 bytes, checksum: bd505129ead7cc5f753979f6f1881a5d (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / Os processos de usinagem são de extrema importância no ramo de indústria metalúrgica, uma vez que quase todas as peças de metais em que se exige uma alta precisão e qualidade de acabamento são produzidas por meio destes processos. Dentre os processos de usinagem destaca-se o processo de retificação, por sua precisão e bom acabamento. É essencial que se conheça bem este processo, já que por ser a última etapa da manufatura, qualquer problema compromente a peça e perde-se o trabalho realizado em todas as etapas anteriores. O presente trabalho visa um estudo comparativo entre a força de corte na retificação medida com um dinamômetro piezelétrico e a potência elétrica do motor que aciona o rebolo. A força de corte é reconhecida como sendo a principal variável de estudos dos processos de usinagem. Tradicionalmente a força de corte é tomada por meio de um dinamômetro, porém este é um dispositivo relativamente caro e de difícil montagem. Usualmente, a força no processo de retificação é tomada por meio de um sensor de corrente, obtendo-se um sinal analógico proporcional à potência consumida pelo motor. Entretanto, esta potência não corresponde à potência mecânica utilizada no corte, e, portanto, imprecisões ocorrem. Neste trabalho, os sinais de potências elétricas e força de corte foram coletados com alta taxa de aquisição, com variações de profundidade de corte e da frequência do motor que aciona o rebolo. Os resultados obtidos mostram que os sinais de potência elétrica do motor que aciona o rebolo sempre foram proporcionais aos sinais de força de corte. Desta forma, é possível o dinamômetro na retificação por sensores de corrente e tensão, com resultados confiáveis. / The machining processes are of great importance in the metallurgical industry, since all the metal workpieces demanding high precision and finishing quality are produced through these processes. Among the machining processes the grinding process can be highlighted by its precision and superior finishing. As being the last manufacturing stage, it is very important to have sound knowledge of the grinding process because minor problems can jeopardize the ground part, and then all the previous manufacturing operations will also be lost. This work aims at comparing the cutting force between the one measured through a piezoelectric dynamometer and that one measured by electrical power of the induction motor that drives the grinding wheel. The cutting force is acknowledged as being the most important variable for studying the machining processes. Traditionally, the cutting force is taken by a piezoelectric dynamometer, which is relatively expensive equipment besides requiring a nontrivial setup. Generally, the cutting force in the grinding process is taken by a Hall Effect current sensor to produce an analog signal proportional to the power consumed by the electric motor. However, that power does not correspond to the mechanical power used to grind, and thus imprecision takes place. In this work, the electric power and cutting force were collected by using a high samplinf the rate acquisition for several cutting depths and two electrical frequencies to drives the induction motor. The results showed the electric power signals behaved, in general, proportional to the cutting force measured by the dynamometer. Thus, the Hall Effect curret and voltage sensors can be replaced by dynamometer in the grinding process with reliable results.

Thesis is indirectly connected to many years of research in field of sulphate binders. Work is focused on modifying of properties of alfa and beta gypsum, mainly on reduction of water ratio. We monitored effect of addition of chloride salts, carbonates and sulphates on zeta potential and its measurement. Part of thesis is also focused on laboratory production of beta plaster from secondary materials and optimization of grinding process to achieve required criteria.

Submitted by PEDRO DE OLIVEIRA CONCEIÇÃO JUNIOR null (pedroliveira931@hotmail.com) on 2016-03-23T18:59:49Z No. of bitstreams: 1 dissertação_exemplar_final.pdf: 5761621 bytes, checksum: 84b8fff3fe34ccd2b227c3763843a3c9 (MD5) / Approved for entry into archive by Ana Paula Grisoto (grisotoana@reitoria.unesp.br) on 2016-03-23T20:05:17Z (GMT) No. of bitstreams: 1 conceicaojunior_po_me_bauru.pdf: 5761621 bytes, checksum: 84b8fff3fe34ccd2b227c3763843a3c9 (MD5) / Made available in DSpace on 2016-03-23T20:05:17Z (GMT). No. of bitstreams: 1 conceicaojunior_po_me_bauru.pdf: 5761621 bytes, checksum: 84b8fff3fe34ccd2b227c3763843a3c9 (MD5) Previous issue date: 2016-02-17 / Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq) / As cerâmicas estruturais avançadas, tais como o óxido de alumínio, nitreto de silício, alumina e a zircônia estão sendo cada vez mais utilizadas na engenharia e na medicina. No entanto, muitas destas características que fazem a cerâmica tão atrativa também dificultam a sua fabri-cação por métodos tradicionais de usinagem. Para obter a forma desejada na usinagem de ma-teriais é necessário o uso do processo de retificação. As características da retificação cerâmicas avançadas são muito diferentes das características dos metais. Portanto, é necessário efetuar outros estudos para alcançar uma compreensão mais abrangente e um melhor controle dos parâmetros. Novas alternativas para o monitoramento do processo de retificação de cerâmicas têm sido estudadas. O monitoramento por sinais de vibração é um dos métodos bem-sucedidos utilizados no processo de retificação, pois algumas características que descrevem o comportamento e a influência do processo nas peças retificadas somente são perceptíveis no estudo deste sinal. O presente trabalho tem como objetivo estudar o sinal de vibração, de for-ma a extrair características relacionadas com o acabamento de cerâmicas avançadas no pro-cesso de retificação plana. Foi utilizada uma máquina retificadora tangencial plana com rebolo diamantado e corpos de prova de cerâmica alumina. O sinal de vibração foi medido por um acelerômetro e coletado por um osciloscópio à taxa de amostragem de 2 MHz. Os ensaios foram realizados em diferentes profundidades de corte, adotando duas velocidades da peça (vw), obtendo condições de usinagem brandas às mais severas. Medições de microscopia con-focal foram realizadas após a retificação das peças com objetivo de caracterizá-las. A rugosi-dade Ra das peças usinadas foi medida em quatro pontos ao longo das mesmas, por meio de um rogosímetro portátil. O processamento digital do sinal de vibração foi realizado, aplicando ferramentas computacionais e estatísticas de análise em cada passada de usinagem, compa-rando com os valores da rugosidade medidos. A faixa de frequência entre 800 Hz e 2 kHz foi a mais interessante para o estudo, e que melhor se relacionou com a condição da cerâmica após a retificação. Foi encontrada uma correlação entre a vibração e a integridade da peça cerâmica, pois o aumento da vibração é diretamente proporcional à rugosidade em cada profundidade de corte utilizada. Infere-se que a vibração pode ser utilizada para monitorar a retificação de cerâmica, devido à sua relação com a condição das peças. / Advanced structural ceramics such as aluminum oxide, silicon, nitride, alumina and zirconia are increasingly being used in engineering and medicine. However, many of these features that make ceramics so attractive also make them difficult to manufacture by traditional machining methods. To obtain the desired shape in the machining of these materials is necessary to use grinding process. The characteristics of the grinding of advanced ceramics are very different from those of metals. Therefore, it is necessary to perform other studies to gain a broader understanding and better control of the parameters. New alternatives for monitoring of ceramic grinding process have been studied. Monitoring vibration signals is one of the successful methods used in the grinding process, as some characteristics that describe the behavior and influence the process in parts ground only are noticeable in the study of this signal. This research aims to study the vibration signal, searching for the extraction of features that best relate to the characterization of machined parts. A surface grinding machine with diamond grinding wheel and alumina ceramic workpieces was used. The vibration signal was measured by an accelerometer and collected by the oscilloscope, using 2 MHz of sample rate. Tests were conducted at different depths of cut, adopting two different feed speeds (vw), which ranged from low to severe grinding conditions. Confocal microscopy was performed after the grinded of the workpieces in order to characterized them. The surface roughness Ra of each finished workpiece was measured at four areas along its surface, using a portable roughness measurer. The vibration digital signal processing was performed by applying computational tools on each pass machining. The frequency range between 800 Hz and 2 kHz was the most interesting for the study, and which better was related to the condition of the ceramic after the grinding process. A correlation between the vibration and the integrity of the ceramic workpiece was found, because the increased vibration is directly proportional to the surface roughness at each depth of cut used. It is inferred that the vibration can be used to monitor the grinding process of ceramic because of its relationship with the condition of the workipiece.

Made available in DSpace on 2014-06-11T19:31:04Z (GMT). No. of bitstreams: 0 Previous issue date: 2007-10-19Bitstream added on 2014-06-13T18:41:35Z : No. of bitstreams: 1 alves_mcs_dr_bauru.pdf: 4541684 bytes, checksum: 03e1d27ea6b721a409bebc9862b0e67f (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / É analisada a influência das técnicas de mínima quantidade de lubrificante (MQL), refrigeração otimizada e refrigeração convencional, com diferentes vazões e velocidade de aplicação do fluido de corte, na qualidade das peças produzidas (acabamento, erros de forma, trincas, queima, perda da dureza) com aços endurecidos, no processo de retificação cilíndrica externa de mergulho com a utilização de rebolos superabrasivos com baixa concentração de CBN. Utilizou-se fluidos de corte de origem vegetal, que representam menos riscos à saúde e ao meio. A análise da qualidade das peças foi realizada através da avaliação das variáveis de saída do processo como o comportamento da força tangencial de corte, energia específica de retificação, rugosidade, desvio de circularidade, emissão acústica, tensão residual, análise de microscopias eletrônicas de varredura e microdureza. Com a análise das formas de aplicação e das várias vazões e velocidades do fluido de corte utilizadas encontraram-se condições de lubri-refrigeração que propiciam a diminuição do volume de fluido de corte, diminuição do tempo de usinagem sem prejudicar os parâmetros geométicos, dimensionais, o acabamento superficial e a integridade superficial dos componentes. Em relação as diferentes formas de aplicação do fluido de corte notou-se o melhor desempenho da aplicação otimizada para maiores velocidades mostrando a eficiência de um novo conceito de bocal utilizado. O processo otimizado e o processo MQL foram capazes de manter a dureza superficial e a integridade superficial das peças produzidas. Exceção somente para a condição MQL com vazão de fluido de corte de 40ml/h que produziu trincas e retêmpera superficial. O desvio de circularidade e a rugosidade proporcionada pelos métodos estão dentro de valores recomendados para a retificação sendo que a técnica otimizada... / The influences on surface integrity of the parts (finishing, geometrical errors, cracks, burn, microhardness) and grinding wheel (wear) have been analyzed in this research by employing the minimum quantity of lubrication (MQL), optimized and conventional cooling for hardened parts of steel and superabrasives grinding wheel in the cylindrical plunge grinding process. This study was carried out through the assessment of the process output variables such as the behavior of the tangential cutting force, specific energy, surface roughness, circularity errors, acoustic emission, residual stress, scanning electronic microscopy (SEM) and microhardness. The cutting fluid derived from vegetal oil has been utilized in order to comply with the environmental requirements and thus offering less risk to the health. It could be observed from the analysis on different ways of cutting fluid applications that there are cooling conditions which facilitate the decrease in cutting fluid volume, decrease in grinding time without impairing the geometrical and dimensional parameters, the surface finish and surface integrity of the parts. It could be noted the optimized application for higher velocities has presented the best performance regarding the different applications of cutting fluids. The optimized and MQL processes were able to maintain the hardness and surface integrity of the ground parts. Exception occurend only for MQL condition with flow rate of 40ml/h, which led to cracks and quench on the workpiece surface. Roundness errors and surface roughness are within recommended valus for grinding with the best results obtained for the optimized method (2'mü' for roundness error and 0.5'mü'm for surface roughness) compared with the MQL technique (6.8'mü'm for roundness error and 1.2'mü'm for surface roughness). The process of minimum quantity of lubrication, however, has showed possible... (Complete abstract click electronic access below)

La rectification est un procédé couramment utilisé dans l’industrie pour la finition des surfaces. L’optimisation du procédé consiste à trouver un compromis entre la qualité des pièces, minimiser les temps d'usinage et augmenter l’efficacité énergétique grâce au choix judicieux des paramètres de rectification. Par ailleurs le taux de production des pièces rectifiées est souvent limité par des contraintes sur la topographie de la surface et des problèmes liés à l’apparition de brûlures de rectification ou de micro-fissures à la surface des pièces. Ces défauts d’aspect engendrent généralement, lorsqu’ils concernent une surface fonctionnelle, une réduction de la durée de vie du composant ainsi rectifié.’effet des conditions de rectification et des propriétés des matériaux sur la nature des contraintes résiduelles a été analysé par modélisation numérique. Le modèle élément finis permet la prédiction non seulement des contraintes résiduelles, mais aussi des phases en présence et des déformations associées. L'objectif de cette étude est de construire un modèle numérique fiable en se basant sur la méthode des éléments finis pour analyser les contraintes résiduelles induites par la rectification et d'explorer, par conséquent, les mécanismes en termes de conditions de rectification. La variation des contraintes résiduelles et des déformations aux points d'intégration a été analysée. Les effets du coefficient de frottement (µ), du nombre de Peclet (Pe), de la conductance de paroi (H) et du flux de chaleur (Q) sur la microstructure et l’état de contraintes résiduelles ont été analysés. Enfin, sur la base des nouveaux résultats de ce travail de recherche, une méthodologie plus complète est proposée pour la suite. / Grinding is a commonly used finishing process to produce components of desired shape, size and dimensional accuracy. The ultimate goal is to have the maximum workpiece quality, minimum machining time and high economic efficiency by making a selective adaptation of the possible process strategy and chosen parameter selection. The focus of this study arose from a limitation that challenges the grinding industry. The production rate of the ground parts is generally constrained by surface topography and subsurface damage appearing as residual tensile stress, localized burns, and phase transformation induced micro and macro-cracking. This motivates the need for a reliable numerical modelling to simulate the grinding process. The numerical model sought should be able to predict not only the required grinding residual stresses but also the deformation history. The objective of this thesis is to build up a reliable finite element model for grinding-induced residual stress analysis and thus to explore thoroughly the mechanisms in terms of grinding conditions. The variations of the residual stresses and strains at integration points have been examined, and the effects of the friction coefficient (µ), Peclet number (Pe), non dimensional heat transfer coefficient (H) and different magnitudes of input heat flux (Q) on both the microstructure and the residual stress state are analyzed. Finally, based on the new findings in this research, a more comprehensive methodology is suggested for further study.

Le procédé de broyage en voie humide est une opération intéressante permettant la production de particules fines ou de nanoparticules. La caractérisation de la taille des particules est une donnée essentielle pour l'interprétation des données, le contrôle et l'optimisation de ces procédés selon divers aspects. Il y a un manque de connaissances relatif à la caractérisation de la taille de particules en relation avec les procédés de broyage en voie humide. Cette caractérisation est spécifique pour différentes raisons. (i) Les dispersions traitées par broyage contiennent souvent des impuretés et (ou) des additifs. Nous savons assez peu comment les impuretés et les additifs influencent la taille des particules en suspension dans ces procédés. (ii) Lors de procédés de broyage en voie humide, des dispersions de différentes concentrations peuvent être utilisées. Il est important de savoir comment la concentration de la dispersion peut influencer la mesure de la taille des particules lors du procédé. (iii) La modification de la taille moyenne des particules, résultant de leur fragmentation, est rapide. (iv) Le degré de polydispersité dans le produit change au cours du temps. (v) La nature des interactions entre les particules change; avant broyage les particules sont non-colloïdales, elles le deviennent après un certain temps d'opération. De même, il y a un manque de connaissances permettant de comprendre comment la qualité du produit broyé final est affectée lors du broyage. Dans cette étude nous explorons plusieurs aspects de la caractérisation de taille et de la qualité du produit au cours d'un procédé de broyage en voie humide du CaCO3, réalisé à l'aide d'un broyeur à billes agité. La spectroscopie acoustique qui est une technique connue pour ses potentialités en matière de caractérisation de taille de dispersions en ligne, sous des conditions réelles de procédés et sans nécessiter une dilution des échantillons, a été utilisée dans cette étude en complément de la diffusion dynamique de la lumière. Ce travail a montré sous quelles conditions les effets des impuretés et des additifs etc. sur la taille des particules en suspension pouvaient être déterminés par spectroscopie acoustique. De plus, nous avons comparé et analysé les résultats des mesures de taille obtenus avec les deux techniques. Les différences observées ont été analysées. Nous avons montré que la diffusion multiple observée à forte concentration en solide lors des procédés de broyage en voie humide pouvait conduire à une mauvaise interprétation des résultats relatifs à la taille des particules. En outre, la qualité est un concept relatif. Dans ce travail, nous avons adopté une démarche pour mesurer les effets de différents paramètres sur les caractéristiques du produit broyé en se basant sur une définition de la qualité telle que dans la norme ISO 9000 :2005. La démarche a permis de prendre en compte différents paramètres opératoires importants (tels que les conditions de fonctionnement du broyeur, la mesure de la taille des particules et les propriétés du matériau), ainsi que différentes propriétés caractéristiques du produit (comme la taille moyenne des particules, la largeur de la distribution de taille, la stabilité de la dispersion, le taux d'impuretés, l'énergie spécifique apportée au système et l'apparence visuelle du produit). Nous avons montré que nous pouvions établir une relation entre les paramètres opératoires et différentes qualités de produits obtenus par un procédé de broyage en voie humide. / Wet grinding process is an interesting means of producing fine and nano particles. The particle sizing plays an important role in interpretation, control and optimization of various aspects of the wet grinding process. There is a lack of knowledge in understanding different aspects of particle sizing during a wet grinding process. The particle sizing in a wet grinding process is typical in the sense: (i) The dispersions in a wet grinding process, often, involve additives and (or) impurities. It is less known how impurities and additives influence the particle size of the dispersions in the wet grinding process. (ii) In a wet grinding process, dispersions of different concentrations may be used. It is less known how dispersions of different concentration may influence the particle sizing in a wet grinding process. (iii) In a wet grinding process, the change in average particle size of the product is rapid due to relatively fast breakage of the particles. (iv) The degree of poly dispersity in product changes with grinding time. (v) The nature of interaction between particles is non-colloidal before grinding process; this interaction becomes colloidal after a certain grinding time. Similarly, there is a lack of knowledge to understand how quality of final ground product is influenced in a wet grinding process. This study investigates the different aspects of particle sizing and product quality of aqueous dispersions of CaCO3 in a wet grinding process carried out in a stirred media mill. Acoustic attenuation spectroscopy that is known for measuring particle size of dispersions on line, under real process conditions and without diluting the sample has been employed in the study in addition to the technique of dynamic light scattering. The study brings out the conditions in which the effects of impurities and additives etc. on particle size of the dispersions may be determined using acoustic attenuation spectroscopy. Furthermore, the study compares and analyze the particle sizing results obtained though acoustic attenuation spectroscopy and dynamic light scattering. The causes of differences in the results of two techniques have been investigated. We report presence of multiple scattering at high concentration of the dispersions during wet grinding process that result in misleading results of the particles sizes. Quality is an intangible concept. In order to understand how different operating parameters influence product quality, we propose a method based upon the definition of quality as defined in ISO 9000:2005. The method takes into consideration the important operating parameters of wet grinding process (such as the operating condition of the mill, the measurement of particle size and the material) and important product characteristics ( such as average particle size, range of width of particle size distribution, stability of dispersion, degree of impurities, specific energy input and physical appearance). We bring out how a relationship between operating parameters and products of different grades may be established in a wet grinding process.

Die Schleifbearbeitung ist häufig ein abschließender Bearbeitungsschritt, dessen Misserfolg zu hohen wirtschaftlichen Verlusten führt. Um im Vorfeld stabile Prozessparameter und optimale Schleifbahnen finden und den Bearbeitungsablauf simulativ testen zu können, werden Modelle benötigt, die die Zusammenhänge über physikalische Gesetzmäßigkeiten abbilden. In dieser Arbeit sind speziell für das Werkzeugschleifen charakteristische Eigenschaften systematisch untersucht und ein Gesamtmodell des Schleifprozesses aufgebaut worden. Die untersuchten Haupteinflüsse sind dabei die aufgrund der starken Geometrieänderung durch den Nutenschleifprozess zeitlich veränderlichen dynamischen Eigenschaften des Werkstücks und die Anregung durch die Rotation und Topographie der Schleifscheibe. Analysiert werden darüber hinaus der Materialabtrag und die Schleifkräfte in Abhängigkeit der Prozessparameter. Die Ergebnisse der Untersuchung dienen als Basis zum Aufbau effizienter, überwiegend auf physikalischen Gesetzmäßigkeiten beruhender Einzelmodelle. Mit dem gekoppelten Gesamtmodell lassen sich Schleifbearbeitungen an einseitig eingespannten und lang auskragenden Werkstücken hochdynamisch und bis zu einigen Minuten abbilden. Es können die Schleifkräfte sowie die Geometriefehler der geschliffenen Werkstücke aufgrund ihrer Durchsenkung berechnet und eine Abschätzung der Werkstücktemperatur durchgeführt werden. Darüber hinaus lässt sich das Schleifmodell zur Anpassung der Schleifbahn nutzen um die Geometriefehler zu reduzieren und die Effizienz der Bearbeitung zu steigern. Durch die physikalisch begründeten Modelle ist die systematische Untersuchung des Schleifens und der Wechselwirkungen möglich, wodurch das Verständnis des Schleifprozesses erweitert wird.:Inhaltsverzeichnis Formelverzeichnis VII Kurzfassung XI Abstract XII 1 Einleitung und Ziel der Arbeit 1 2 Stand desWissens und der Forschung 4 2.1 Modellvorstellung des Schleifprozesses 5 2.2 Schleifprozessmodelle 7 2.2.1 Kinematikmodelle 9 2.2.2 Schleifkraftmodelle 14 2.2.3 Temperaturmodelle 17 2.3 Prozessdynamik 19 2.3.1 Schwingungen 19 2.3.2 Rattererkennung im Zeitbereich 21 2.3.3 Rattererkennung im Frequenzbereich 22 3 Analyse und Modellierung der Systemstruktur 24 3.1 Charakterisierung der Dynamikeigenschaften des Werkstücks 26 3.2 Maschinentisch und Werkstückeinspannung 29 3.3 Modellierung der Werkstückstruktur 34 3.4 Parameterbestimmung für das Strukturmodell und Einflussanalyse 41 4 Analyse und Modellierung der Anregungsmechanismen 51 4.1 Dynamische Einflüsse beim Schleifen 51 4.2 Charakterisierung der Schleifscheibeneinflüsse auf die Werkstückdynamik 53 4.3 Modellierung der Schleifscheibentopographie 56 4.4 Schleifscheibenverschleiß 63 4.5 Implementierung des Schleifscheibenmodells im Gesamtmodell 67 5 Kontaktmodellierung und Prozesseinflussanalyse 69 5.1 Kontaktanalyse und Schleifkraftberechnung 69 5.2 Materialabtragsmodellierung 78 5.3 Prozesseinflussanalyse auf die Schleifkraft 83 5.3.1 Einfluss der Schleifscheibentopographie 84 5.3.2 Einfluss der Prozessparameter 89 5.4 Prozesseinflußanalyse auf die Werkstückgeometrie 93 5.4.1 Parametereinfluss auf die Werkstückgeometrie 93 5.4.2 Parametereinfluss auf die Rauheit der geschliffenen Werkstückoberfläche 95 6 Temperaturmodellierung 99 6.1 Grundmodelle bewegter Wärmequellen 99 6.2 Erweiterungen zur Abbildung von Schleifprozessen 102 7 Gesamtsimulation des Werkzeugschleifens 109 7.1 Einfluss der Simulationsmodule 112 7.2 Variation der Prozessparameter 115 7.3 Variation der Werkstückgeometrie 121 7.4 Variation des Werkstückquerschnitts 124 7.5 Kinematikvariation zur Verbesserung der Formhaltigkeit 129 8 Zusammenfassung 131 A Unterteilung der Fertigungsverfahren 135 B Mathematische Grundlagen 136 B.1 Herleitung der Ansatzfunktionen und Systemmatritzen 136 B.2 Partikuläre Lösung für Systeme mit Fremderregung 141 C Analytische Beschreibung der Kontaktfläche von Werkstücken mit Spiralnut 143 D Simulationsergebnisse 145 D.1 Simulationsergebnis des Längsnutenschleifens 145 D.2 Einfluss der Simulationsmodule 146 D.3 Variation der Prozessparameter 147 D.4 Variation der Werkstückgeometrie 149 D.5 Variation der auskragenden Werkstücklänge 150 D.6 Variation des Werkstückquerschnitts 151 Literatur / As final machine processing mostly grinding is used so failure of this production step leads to high economic losses. To avoid instable process condition, to adapt the grinding wheel path, and to simulate grinding setups in advance, efficient and physically based models are need. In this work especially the tool grinding process is analysed and characteristically effects are investigated to build up an overall grinding model. The main effects are thereby the time variant dynamical properties of the workpiece due to strong geometry changes during the flute grinding process and the excitation due to the rotation and topography of the grinding wheel. Additionally analysis of the contact conditions and grinding forces in dependency of the predefined process parameters are carried out. Based on the results of these investigation efficient models are build up to represent the behaviour mostly by physical laws. With the coupled model, grinding processes of one-sided clamped and long cantilevering workpieces can be simulated high dynamically over several minutes. It is possible to predict grinding forces and geometry errors of the ground flute due to deformation of the workpiece. Additionally the temperature of the workpiece can be estimated. Furthermore the grinding wheel path can be adapted and tested to reduce geometrical errors and to increase the efficiency of the manufacturing process. With these physically based models systematically investigations of the grinding process and the interaction are possible. With this simulation the understanding of grinding can be enhanced which is important to adapt the manufacturing process.:Inhaltsverzeichnis Formelverzeichnis VII Kurzfassung XI Abstract XII 1 Einleitung und Ziel der Arbeit 1 2 Stand desWissens und der Forschung 4 2.1 Modellvorstellung des Schleifprozesses 5 2.2 Schleifprozessmodelle 7 2.2.1 Kinematikmodelle 9 2.2.2 Schleifkraftmodelle 14 2.2.3 Temperaturmodelle 17 2.3 Prozessdynamik 19 2.3.1 Schwingungen 19 2.3.2 Rattererkennung im Zeitbereich 21 2.3.3 Rattererkennung im Frequenzbereich 22 3 Analyse und Modellierung der Systemstruktur 24 3.1 Charakterisierung der Dynamikeigenschaften des Werkstücks 26 3.2 Maschinentisch und Werkstückeinspannung 29 3.3 Modellierung der Werkstückstruktur 34 3.4 Parameterbestimmung für das Strukturmodell und Einflussanalyse 41 4 Analyse und Modellierung der Anregungsmechanismen 51 4.1 Dynamische Einflüsse beim Schleifen 51 4.2 Charakterisierung der Schleifscheibeneinflüsse auf die Werkstückdynamik 53 4.3 Modellierung der Schleifscheibentopographie 56 4.4 Schleifscheibenverschleiß 63 4.5 Implementierung des Schleifscheibenmodells im Gesamtmodell 67 5 Kontaktmodellierung und Prozesseinflussanalyse 69 5.1 Kontaktanalyse und Schleifkraftberechnung 69 5.2 Materialabtragsmodellierung 78 5.3 Prozesseinflussanalyse auf die Schleifkraft 83 5.3.1 Einfluss der Schleifscheibentopographie 84 5.3.2 Einfluss der Prozessparameter 89 5.4 Prozesseinflußanalyse auf die Werkstückgeometrie 93 5.4.1 Parametereinfluss auf die Werkstückgeometrie 93 5.4.2 Parametereinfluss auf die Rauheit der geschliffenen Werkstückoberfläche 95 6 Temperaturmodellierung 99 6.1 Grundmodelle bewegter Wärmequellen 99 6.2 Erweiterungen zur Abbildung von Schleifprozessen 102 7 Gesamtsimulation des Werkzeugschleifens 109 7.1 Einfluss der Simulationsmodule 112 7.2 Variation der Prozessparameter 115 7.3 Variation der Werkstückgeometrie 121 7.4 Variation des Werkstückquerschnitts 124 7.5 Kinematikvariation zur Verbesserung der Formhaltigkeit 129 8 Zusammenfassung 131 A Unterteilung der Fertigungsverfahren 135 B Mathematische Grundlagen 136 B.1 Herleitung der Ansatzfunktionen und Systemmatritzen 136 B.2 Partikuläre Lösung für Systeme mit Fremderregung 141 C Analytische Beschreibung der Kontaktfläche von Werkstücken mit Spiralnut 143 D Simulationsergebnisse 145 D.1 Simulationsergebnis des Längsnutenschleifens 145 D.2 Einfluss der Simulationsmodule 146 D.3 Variation der Prozessparameter 147 D.4 Variation der Werkstückgeometrie 149 D.5 Variation der auskragenden Werkstücklänge 150 D.6 Variation des Werkstückquerschnitts 151 Literatur

This thesis covers the process of automating the design of coolant nozzles used for cylindrical grinding. Coolant nozzles are used to supply coolant, an oil and water mixture used to cool the metal workpiece and lubricate the grinding wheel. In the automotive industry, grinding is used to reduce the surface roughness of the workpiece. However, a large amount of heat is generated, risking the heat treatment of the steel to be compromised, for this, coolant is supplied to minimize the heat caused by friction. A nozzle is used, aiming a jet to the zone that generates heat. Commonly used nozzles are adjustable, leading to variation in cooling performance if misaligned. The design of fixed nozzles is developed in this thesis to reduce variation and automatise the design for multiple applications. The automatically designed nozzles are fused deposition modeled and tested. The design automation tool is tested repeatedly and improved successively in the span of the thesis. This lead to a great extent of implementation of design automation. Which lead to a facilitation in reaching of the work zone and avoid obstacles. Also, the tool managed to create nozzle tubes for a multitude of machines. The tool is able to generate, aim, orient, and individually dimension multi-nozzle tubes. Design of Experiment methodology is implemented to find nozzle designs with improved velocity and flow rate and minimize the air mixture with the coolant. Several nozzle designs are tested and fitted into a surrogate model that is, in turn, optimized. The results of the tests led to a greater understanding of how the nozzle geometry restricts the flow rate when attempts of reaching higher velocities of the coolant jet are made. The surrogate models created, also made it possible to find the range of designs which best suits different applications, whereby a Pareto front was able to be populated with a range of different designs alternating in flow rate, velocity and coherency ratio.