Determination of Static and Dynamic Deflections in Tool Grinding using a Dexel-Based Material Removal Simulation.

In this paper a modeling approach is presented to simulate static and dynamic deflections in tool grinding considering the geometric changes of the ground tool. The approach couples a dexel-based material removal model with a kinematics model, a grinding force model and a mechanical deflection model. The tool’s 3D-shape is modeled as a regular grid of “dexels” (depth elements) which makes it possible to calculate material removal and local engagement parameters at discrete grinding wheel locations. With a combined empirical and finite element grinding force model for the microscopic grain contact the stress distribution in the contact area can be calculated for different engagement parameters. The static and dynamic tool deflections are calculated using an Euler-Bernoulli beam equation and modal reduction algorithms, taking changing geometrical moments of inertia into account. Finally, the modeling approach is compared with experimental results conducted on an industrial tool grinding machine.