The Experts below are selected from a list of 12822 Experts worldwide ranked by ideXlab platform
Fritz Klocke - One of the best experts on this subject based on the ideXlab platform.
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Influence of different Grinding Wheel and dressing roller specifications on Grinding Wheel wear
Production Engineering, 2018Co-Authors: Sebastian Prinz, Daniel Trauth, Patrick Mattfeld, Fritz KlockeAbstract:A targeted adjustment of the dressing results and the methodological influence of the dressing process on the non-stationary wear of a Grinding Wheel after dressing increases the productivity and the reproducibility of Grinding processes. Despite the great economic importance of Grinding processes with vitrified corundum Grinding Wheels and the great relevance of the dressing process for the application behavior of these Grinding Wheels, quantitative models are missing for the purposeful design of the dressing process. In previous studies, a dressing model was successfully developed which predicts the dressing force in the dressing process as well as the workpiece roughness and the Grinding Wheel wear behavior in a Grinding process for a specific Grinding Wheel and form roller specification. However, a transferability of this model to other Grinding Wheel and form roller specifications is not possible because the influence of the grain size and the hardness of the Grinding Wheel as well as the dressing tool topography on the Grinding Wheel wear and thus on parameters of the dressing model are not known. The objective of this work was to extend the model to additional Grinding Wheel and form roller specifications to ensure a broad applicability of the model.
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Modeling of the Grinding Wheel Topography Depending on the Recipe-Dependent Volumetric Composition
Journal of Manufacturing Science and Engineering-transactions of The Asme, 2017Co-Authors: Sebastian Barth, Michael Rom, Christian Wrobel, Fritz KlockeAbstract:The prediction of the Grinding process result, such as the workpiece surface quality or the state of the edge zone depending on the used Grinding Wheel is still a great challenge for today's manufacturers and users of Grinding tools. This is mainly caused by an inadequate predictability of force and temperature affecting the process. The force and the temperature strongly depend on the topography of the Grinding Wheel, which comes into contact with the workpiece during the Grinding process. The topography of a Grinding Wheel mainly depends on the structure of the Grinding Wheel, which is determined by the recipe-dependent volumetric composition of the tool. So, the structure of a Grinding tool determines its application behavior strongly. As result, the knowledge-based prediction of the Grinding Wheel topography and its influence on the machining behavior will only be possible if the recipe-dependent Grinding Wheel structure is known. This paper presents an innovative approach for modeling the Grinding Wheel structure and the resultant Grinding Wheel topography. The overall objective of the underlying research work was to create a mathematical-generic Grinding tool model in which the spatial arrangement of the components, grains, bond, and pores, is simulated in a realistic manner starting from the recipe-dependent volumetric composition of a Grinding Wheel. This model enables the user to determine the resulting Grinding Wheel structure and the Grinding Wheel topography of vitrified and synthetic resin-bonded cubic boron nitride (CBN) Grinding Wheels depending on their specification and thus to predict their application behavior. The originality of the present research results is a generic approach for the modeling of Grinding tools, which takes into account the entire Grinding Wheel structure to build up the topography. Therefore, original mathematical methods are used. The components of Grinding Wheels are analyzed, and distribution functions of the component's positions in the tools are determined. Thus, the statistical character of the Grinding Wheel structure is taken into account in the developed model. In future, the presented model opens new perspectives in order to optimize and to increase the productivity of Grinding processes.
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Modeling of the Grinding Wheel Topography Depending on the Recipe-Dependent Volumetric Composition
Volume 1: Processes, 2017Co-Authors: Fritz Klocke, Sebastian Barth, Michael Rom, Christian WrobelAbstract:The prediction of the Grinding process result, such as the workpiece surface quality or the state of the edge zone depending on the used Grinding Wheel is a great challenge for todays manufacturers and users of Grinding tools. This is mainly caused by inadequate predictability of the forces and temperatures acting in the process, which depend on the topography of the Grinding Wheel coming into contact with the workpiece during the Grinding process. The topography of a Grinding Wheel depends, beside the dressing process, on the structure of the Grinding Wheel, which is determined by its recipe-dependent volumetric composition. The structure of a Grinding tool therefore determines its application behavior strongly. As a result, the knowledge-based prediction of the Grinding Wheel topography and its influence on the machining behavior is only possible if the recipe-dependent Grinding Wheel structure is known. In this paper, an innovative approach for modeling the Grinding Wheel structure and the resultant Grinding Wheel topography is discussed. The overall objective of the underlying research project was to create a mathematical-generic Grinding Wheel model in which the spatial arrangement of the components grains, bond and pores is simulated in a realistic manner starting from the recipe-dependent volumetric composition of a Grinding Wheel. With this model it is possible to determine the resulting Grinding Wheel structure and the Grinding Wheel topography of vitrified and synthetic resin-bonded CBN Grinding Wheels and thus to predict their application behavior. The originality of the present research results is a generic approach for the modeling of Grinding Wheels, taking into account the entire Grinding Wheel structure and build up the topography based on it. Using original mathematical methods, the components of Grinding Wheels were analyzed and distribution functions of the components were determined. Thus the statistical character of the Grinding Wheel structure was taken into account. In future, the presented model opens new perspectives in order to optimize and to increase the productivity of Grinding processes.
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DETAILED ANALYSIS AND DESCRIPTION OF Grinding Wheel TOPOGRAPHIES
Journal of Manufacturing Science and Engineering-transactions of The Asme, 2017Co-Authors: Markus Weiß, Fritz Klocke, Sebastian Barth, Matthias Rasim, Patrick MattfeldAbstract:In this paper, an innovative approach for the description of the functional properties of a Grinding Wheel surface is discussed. First, the state of the art in the description of Grinding Wheel topographies is summarized. Furthermore, the fundamentals for a new approach for the quantitative description of Grinding Wheel topographies are provided. In order to analyze the functional properties of a Grinding Wheel's topography depending on its specification, Grinding experiments were carried out. For the experimental investigations vitrified, synthetic resin bonded and electroplated Grinding Wheels with varied compositions were analyzed. During the experiments, the topographies of the investigated Grinding Wheels have been analyzed by means of the topotool in detail. The developed software tool allows a detailed description of the kinematic cutting edges depending on the Grinding process parameters and the Grinding Wheel specification. In addition to the calculation of the number of kinematic cutting edges and the area per cutting edge, a differentiation of the cutting edge areas in normal and tangential areas of the Grinding Wheel's circumferential direction is implemented. Furthermore, the topotool enables to analyze the kinematic cutting edges shape by calculating the angles of the grain in different directions. This enables a detailed analysis and a quantitative comparison of Grinding Wheel topographies related to different Grinding Wheel specifications. In addition, the influence of the dressing process and wear conditions to the Grinding Wheel topography can be evaluated. The new approach allows a better characterization of the contact conditions between Grinding Wheel and workpiece. Hence, the impact of a specific topography on the Grinding process behavior, the generated Grinding energy distribution, and the Grinding result can be revealed.
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Modelling of the Grinding Wheel Structure Depending on the Volumetric Composition
Procedia CIRP, 2016Co-Authors: Fritz Klocke, Patrick Mattfeld, Markus Weiß, Sebastian Barth, Karl-heinz Brakhage, Christian Wrobel, Michael RomAbstract:Abstract The volumetric composition of a Grinding Wheel is decisive for its structure and topography properties. However, the application-specific choice of Grinding Wheels is commonly based on experience. To enable a knowledge-based selection of Grinding Wheels, the WZL and the IGPM of the RWTH Aachen University develop a mathematical model in order to simulate the structure and the topography of a Grinding Wheel dependent on its volumetric composition. This paper presents a numerical model, which allows the simulation and display of the Grinding Wheel structure depending on its volumetric composition. Thereby, the grain morphology, the grain size distribution as well as pores and different bonding types are considered. Furthermore, a method to verify the results of the model is introduced and the correlation between the simulation and the real Grinding Wheel structure is shown.
Sebastian Barth - One of the best experts on this subject based on the ideXlab platform.
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Modeling of the Grinding Wheel Topography Depending on the Recipe-Dependent Volumetric Composition
Journal of Manufacturing Science and Engineering-transactions of The Asme, 2017Co-Authors: Sebastian Barth, Michael Rom, Christian Wrobel, Fritz KlockeAbstract:The prediction of the Grinding process result, such as the workpiece surface quality or the state of the edge zone depending on the used Grinding Wheel is still a great challenge for today's manufacturers and users of Grinding tools. This is mainly caused by an inadequate predictability of force and temperature affecting the process. The force and the temperature strongly depend on the topography of the Grinding Wheel, which comes into contact with the workpiece during the Grinding process. The topography of a Grinding Wheel mainly depends on the structure of the Grinding Wheel, which is determined by the recipe-dependent volumetric composition of the tool. So, the structure of a Grinding tool determines its application behavior strongly. As result, the knowledge-based prediction of the Grinding Wheel topography and its influence on the machining behavior will only be possible if the recipe-dependent Grinding Wheel structure is known. This paper presents an innovative approach for modeling the Grinding Wheel structure and the resultant Grinding Wheel topography. The overall objective of the underlying research work was to create a mathematical-generic Grinding tool model in which the spatial arrangement of the components, grains, bond, and pores, is simulated in a realistic manner starting from the recipe-dependent volumetric composition of a Grinding Wheel. This model enables the user to determine the resulting Grinding Wheel structure and the Grinding Wheel topography of vitrified and synthetic resin-bonded cubic boron nitride (CBN) Grinding Wheels depending on their specification and thus to predict their application behavior. The originality of the present research results is a generic approach for the modeling of Grinding tools, which takes into account the entire Grinding Wheel structure to build up the topography. Therefore, original mathematical methods are used. The components of Grinding Wheels are analyzed, and distribution functions of the component's positions in the tools are determined. Thus, the statistical character of the Grinding Wheel structure is taken into account in the developed model. In future, the presented model opens new perspectives in order to optimize and to increase the productivity of Grinding processes.
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Modeling of the Grinding Wheel Topography Depending on the Recipe-Dependent Volumetric Composition
Volume 1: Processes, 2017Co-Authors: Fritz Klocke, Sebastian Barth, Michael Rom, Christian WrobelAbstract:The prediction of the Grinding process result, such as the workpiece surface quality or the state of the edge zone depending on the used Grinding Wheel is a great challenge for todays manufacturers and users of Grinding tools. This is mainly caused by inadequate predictability of the forces and temperatures acting in the process, which depend on the topography of the Grinding Wheel coming into contact with the workpiece during the Grinding process. The topography of a Grinding Wheel depends, beside the dressing process, on the structure of the Grinding Wheel, which is determined by its recipe-dependent volumetric composition. The structure of a Grinding tool therefore determines its application behavior strongly. As a result, the knowledge-based prediction of the Grinding Wheel topography and its influence on the machining behavior is only possible if the recipe-dependent Grinding Wheel structure is known. In this paper, an innovative approach for modeling the Grinding Wheel structure and the resultant Grinding Wheel topography is discussed. The overall objective of the underlying research project was to create a mathematical-generic Grinding Wheel model in which the spatial arrangement of the components grains, bond and pores is simulated in a realistic manner starting from the recipe-dependent volumetric composition of a Grinding Wheel. With this model it is possible to determine the resulting Grinding Wheel structure and the Grinding Wheel topography of vitrified and synthetic resin-bonded CBN Grinding Wheels and thus to predict their application behavior. The originality of the present research results is a generic approach for the modeling of Grinding Wheels, taking into account the entire Grinding Wheel structure and build up the topography based on it. Using original mathematical methods, the components of Grinding Wheels were analyzed and distribution functions of the components were determined. Thus the statistical character of the Grinding Wheel structure was taken into account. In future, the presented model opens new perspectives in order to optimize and to increase the productivity of Grinding processes.
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DETAILED ANALYSIS AND DESCRIPTION OF Grinding Wheel TOPOGRAPHIES
Journal of Manufacturing Science and Engineering-transactions of The Asme, 2017Co-Authors: Markus Weiß, Fritz Klocke, Sebastian Barth, Matthias Rasim, Patrick MattfeldAbstract:In this paper, an innovative approach for the description of the functional properties of a Grinding Wheel surface is discussed. First, the state of the art in the description of Grinding Wheel topographies is summarized. Furthermore, the fundamentals for a new approach for the quantitative description of Grinding Wheel topographies are provided. In order to analyze the functional properties of a Grinding Wheel's topography depending on its specification, Grinding experiments were carried out. For the experimental investigations vitrified, synthetic resin bonded and electroplated Grinding Wheels with varied compositions were analyzed. During the experiments, the topographies of the investigated Grinding Wheels have been analyzed by means of the topotool in detail. The developed software tool allows a detailed description of the kinematic cutting edges depending on the Grinding process parameters and the Grinding Wheel specification. In addition to the calculation of the number of kinematic cutting edges and the area per cutting edge, a differentiation of the cutting edge areas in normal and tangential areas of the Grinding Wheel's circumferential direction is implemented. Furthermore, the topotool enables to analyze the kinematic cutting edges shape by calculating the angles of the grain in different directions. This enables a detailed analysis and a quantitative comparison of Grinding Wheel topographies related to different Grinding Wheel specifications. In addition, the influence of the dressing process and wear conditions to the Grinding Wheel topography can be evaluated. The new approach allows a better characterization of the contact conditions between Grinding Wheel and workpiece. Hence, the impact of a specific topography on the Grinding process behavior, the generated Grinding energy distribution, and the Grinding result can be revealed.
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Modelling of the Grinding Wheel Structure Depending on the Volumetric Composition
Procedia CIRP, 2016Co-Authors: Fritz Klocke, Patrick Mattfeld, Markus Weiß, Sebastian Barth, Karl-heinz Brakhage, Christian Wrobel, Michael RomAbstract:Abstract The volumetric composition of a Grinding Wheel is decisive for its structure and topography properties. However, the application-specific choice of Grinding Wheels is commonly based on experience. To enable a knowledge-based selection of Grinding Wheels, the WZL and the IGPM of the RWTH Aachen University develop a mathematical model in order to simulate the structure and the topography of a Grinding Wheel dependent on its volumetric composition. This paper presents a numerical model, which allows the simulation and display of the Grinding Wheel structure depending on its volumetric composition. Thereby, the grain morphology, the grain size distribution as well as pores and different bonding types are considered. Furthermore, a method to verify the results of the model is introduced and the correlation between the simulation and the real Grinding Wheel structure is shown.
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Detailed Analysis and Description of Grinding Wheel Topographies
Volume 1: Processing, 2015Co-Authors: Markus Weiß, Fritz Klocke, Sebastian Barth, Matthias Rasim, Patrick MattfeldAbstract:In this paper, an innovative approach for the description of the functional properties of a Grinding Wheel surface is discussed. First, the state of the art in the description of Grinding Wheel topographies is summarized. Furthermore, the fundamentals for a new approach for the quantitative description of Grinding Wheel topographies are provided. In order to analyze the functional properties of a Grinding Wheel’s topography depending on its specification, Grinding experiments were carried out. For the experimental investigations both vitrified and synthetic resin bonded Grinding Wheels with varied compositions were analyzed.During the experiments, the topographies of the investigated Grinding Wheel surfaces have been analyzed in detail. The developed software tool allows for a detailed description of the kinematic cutting edges depending on the Grinding process parameters and the Grinding Wheel. In addition to the calculation of the number of kinematic cutting edges and the area per cutting edge a differentiation of the cutting edge areas in normal and tangential areas of the Grinding Wheel’s circumferential direction is implemented. This enables a detailed analysis and a quantitative comparison of Grinding Wheel topographies related to different Grinding Wheel specifications. In addition, the influence of the dressing process and wear conditions can be evaluated. The new approach allows a better characterization of the contact conditions between Grinding Wheel and workpiece. Hence, the impact of a specific topography on the Grinding process behavior and the Grinding result can be revealed.Copyright © 2015 by ASME
Christian Wrobel - One of the best experts on this subject based on the ideXlab platform.
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Modeling of the Grinding Wheel Topography Depending on the Recipe-Dependent Volumetric Composition
Journal of Manufacturing Science and Engineering-transactions of The Asme, 2017Co-Authors: Sebastian Barth, Michael Rom, Christian Wrobel, Fritz KlockeAbstract:The prediction of the Grinding process result, such as the workpiece surface quality or the state of the edge zone depending on the used Grinding Wheel is still a great challenge for today's manufacturers and users of Grinding tools. This is mainly caused by an inadequate predictability of force and temperature affecting the process. The force and the temperature strongly depend on the topography of the Grinding Wheel, which comes into contact with the workpiece during the Grinding process. The topography of a Grinding Wheel mainly depends on the structure of the Grinding Wheel, which is determined by the recipe-dependent volumetric composition of the tool. So, the structure of a Grinding tool determines its application behavior strongly. As result, the knowledge-based prediction of the Grinding Wheel topography and its influence on the machining behavior will only be possible if the recipe-dependent Grinding Wheel structure is known. This paper presents an innovative approach for modeling the Grinding Wheel structure and the resultant Grinding Wheel topography. The overall objective of the underlying research work was to create a mathematical-generic Grinding tool model in which the spatial arrangement of the components, grains, bond, and pores, is simulated in a realistic manner starting from the recipe-dependent volumetric composition of a Grinding Wheel. This model enables the user to determine the resulting Grinding Wheel structure and the Grinding Wheel topography of vitrified and synthetic resin-bonded cubic boron nitride (CBN) Grinding Wheels depending on their specification and thus to predict their application behavior. The originality of the present research results is a generic approach for the modeling of Grinding tools, which takes into account the entire Grinding Wheel structure to build up the topography. Therefore, original mathematical methods are used. The components of Grinding Wheels are analyzed, and distribution functions of the component's positions in the tools are determined. Thus, the statistical character of the Grinding Wheel structure is taken into account in the developed model. In future, the presented model opens new perspectives in order to optimize and to increase the productivity of Grinding processes.
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Modeling of the Grinding Wheel Topography Depending on the Recipe-Dependent Volumetric Composition
Volume 1: Processes, 2017Co-Authors: Fritz Klocke, Sebastian Barth, Michael Rom, Christian WrobelAbstract:The prediction of the Grinding process result, such as the workpiece surface quality or the state of the edge zone depending on the used Grinding Wheel is a great challenge for todays manufacturers and users of Grinding tools. This is mainly caused by inadequate predictability of the forces and temperatures acting in the process, which depend on the topography of the Grinding Wheel coming into contact with the workpiece during the Grinding process. The topography of a Grinding Wheel depends, beside the dressing process, on the structure of the Grinding Wheel, which is determined by its recipe-dependent volumetric composition. The structure of a Grinding tool therefore determines its application behavior strongly. As a result, the knowledge-based prediction of the Grinding Wheel topography and its influence on the machining behavior is only possible if the recipe-dependent Grinding Wheel structure is known. In this paper, an innovative approach for modeling the Grinding Wheel structure and the resultant Grinding Wheel topography is discussed. The overall objective of the underlying research project was to create a mathematical-generic Grinding Wheel model in which the spatial arrangement of the components grains, bond and pores is simulated in a realistic manner starting from the recipe-dependent volumetric composition of a Grinding Wheel. With this model it is possible to determine the resulting Grinding Wheel structure and the Grinding Wheel topography of vitrified and synthetic resin-bonded CBN Grinding Wheels and thus to predict their application behavior. The originality of the present research results is a generic approach for the modeling of Grinding Wheels, taking into account the entire Grinding Wheel structure and build up the topography based on it. Using original mathematical methods, the components of Grinding Wheels were analyzed and distribution functions of the components were determined. Thus the statistical character of the Grinding Wheel structure was taken into account. In future, the presented model opens new perspectives in order to optimize and to increase the productivity of Grinding processes.
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Modelling of the Grinding Wheel Structure Depending on the Volumetric Composition
Procedia CIRP, 2016Co-Authors: Fritz Klocke, Patrick Mattfeld, Markus Weiß, Sebastian Barth, Karl-heinz Brakhage, Christian Wrobel, Michael RomAbstract:Abstract The volumetric composition of a Grinding Wheel is decisive for its structure and topography properties. However, the application-specific choice of Grinding Wheels is commonly based on experience. To enable a knowledge-based selection of Grinding Wheels, the WZL and the IGPM of the RWTH Aachen University develop a mathematical model in order to simulate the structure and the topography of a Grinding Wheel dependent on its volumetric composition. This paper presents a numerical model, which allows the simulation and display of the Grinding Wheel structure depending on its volumetric composition. Thereby, the grain morphology, the grain size distribution as well as pores and different bonding types are considered. Furthermore, a method to verify the results of the model is introduced and the correlation between the simulation and the real Grinding Wheel structure is shown.
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Mathematical Modeling of Grinding Wheel Structures
2015Co-Authors: Michael Rom, Patrick Mattfeld, Sebastian Barth, Karl-heinz Brakhage, Christian Wrobel, Fritz KlockeAbstract:The proper choice of a Grinding tool is essential for a productive Grinding process and a high quality of the resulting work piece surface. Therefore, the Grinding Wheel structure consisting of abrasive grain material, bonding material and pores has to be composed wisely. Since this process is nearly exclusively based on experience, it can be very expensive and time-consuming. In this work, we present a new approach for mathematically modeling the Grinding Wheel structure with the objective of predicting the volumetric composition of the Grinding Wheel components such that Grinding requirements can be met without using trial and error methods. For the development of a mathematical model, we focus on a small element of a Grinding Wheel, such as a cube, which we call volumetric structure element (VSE). Input parameters like the grain, bond and pore volumes and the distribution of grain sizes and shapes determine the structure of the VSE. The grains can be chosen from convex polyhedrons or from scan data obtained from computer tomography (CT). In the latter case, the grains can be non-convex. The convex polyhedrons can be modified by randomly changing angles and edge lengths and by randomly choosing planes to cut off corners or edges of the polyhedrons. Each grain is represented by a triangle mesh which is generated by applying the quickhull algorithm in the convex case and the marching cubes algorithm with an optional subsequent simplification in the CT case. The grains can be moved collision-free in the VSE to obtain the required grain volume fraction prescribed by the particular Grinding Wheel specification. Therefore, an iterative algorithm incorporating the bounding sphere of each grain is applied. For modeling the Grinding Wheel topography, intersecting planes through the VSE can be calculated. The change of the topography, i.e., of the grains and of the bond, depends on statistical distribution functions for grain fracturing, grain break-out and bond fracturing determined by experiments. Every single grain of the Grinding Wheel surface is then analyzed, e.g., regarding the volume fraction of a grain protruding from the bond. If a critical ratio of that volume fraction to that of the attached bond is exceeded, the grain breaks out.
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Mathematical Modeling of Ceramic-Bonded Grinding Wheel Structures
2015Co-Authors: Michael Rom, Fritz Klocke, Sebastian Barth, Karl-heinz Brakhage, P. Mattfeld, Christian WrobelAbstract:The proper choice of a Grinding tool is essential for a productive Grinding process and a high quality of the resulting work piece surface. Hence, the Grinding Wheel structure consisting of abrasive grain material, bonding material and pores has to be composed wisely. We present a new approach for mathematically modeling such Grinding Wheel structures with the objective of predicting the volumetric composition of the Grinding Wheel components such that Grinding requirements can be met without using trial and error methods. For the model, we focus on a small element of a Grinding Wheel, such as a cube, which we call volumetric structure element (VSE). In this paper, we concentrate on several aspects of the modeling procedure, namely the initial grain arrangement, a collision-free grain rotation and translation algorithm to obtain required grain volume fractions in a VSE, the tetrahedral mesh generation for a whole VSE and the modeling of ceramic bond.
Michael Rom - One of the best experts on this subject based on the ideXlab platform.
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Modeling of the Grinding Wheel Topography Depending on the Recipe-Dependent Volumetric Composition
Journal of Manufacturing Science and Engineering-transactions of The Asme, 2017Co-Authors: Sebastian Barth, Michael Rom, Christian Wrobel, Fritz KlockeAbstract:The prediction of the Grinding process result, such as the workpiece surface quality or the state of the edge zone depending on the used Grinding Wheel is still a great challenge for today's manufacturers and users of Grinding tools. This is mainly caused by an inadequate predictability of force and temperature affecting the process. The force and the temperature strongly depend on the topography of the Grinding Wheel, which comes into contact with the workpiece during the Grinding process. The topography of a Grinding Wheel mainly depends on the structure of the Grinding Wheel, which is determined by the recipe-dependent volumetric composition of the tool. So, the structure of a Grinding tool determines its application behavior strongly. As result, the knowledge-based prediction of the Grinding Wheel topography and its influence on the machining behavior will only be possible if the recipe-dependent Grinding Wheel structure is known. This paper presents an innovative approach for modeling the Grinding Wheel structure and the resultant Grinding Wheel topography. The overall objective of the underlying research work was to create a mathematical-generic Grinding tool model in which the spatial arrangement of the components, grains, bond, and pores, is simulated in a realistic manner starting from the recipe-dependent volumetric composition of a Grinding Wheel. This model enables the user to determine the resulting Grinding Wheel structure and the Grinding Wheel topography of vitrified and synthetic resin-bonded cubic boron nitride (CBN) Grinding Wheels depending on their specification and thus to predict their application behavior. The originality of the present research results is a generic approach for the modeling of Grinding tools, which takes into account the entire Grinding Wheel structure to build up the topography. Therefore, original mathematical methods are used. The components of Grinding Wheels are analyzed, and distribution functions of the component's positions in the tools are determined. Thus, the statistical character of the Grinding Wheel structure is taken into account in the developed model. In future, the presented model opens new perspectives in order to optimize and to increase the productivity of Grinding processes.
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Modeling of the Grinding Wheel Topography Depending on the Recipe-Dependent Volumetric Composition
Volume 1: Processes, 2017Co-Authors: Fritz Klocke, Sebastian Barth, Michael Rom, Christian WrobelAbstract:The prediction of the Grinding process result, such as the workpiece surface quality or the state of the edge zone depending on the used Grinding Wheel is a great challenge for todays manufacturers and users of Grinding tools. This is mainly caused by inadequate predictability of the forces and temperatures acting in the process, which depend on the topography of the Grinding Wheel coming into contact with the workpiece during the Grinding process. The topography of a Grinding Wheel depends, beside the dressing process, on the structure of the Grinding Wheel, which is determined by its recipe-dependent volumetric composition. The structure of a Grinding tool therefore determines its application behavior strongly. As a result, the knowledge-based prediction of the Grinding Wheel topography and its influence on the machining behavior is only possible if the recipe-dependent Grinding Wheel structure is known. In this paper, an innovative approach for modeling the Grinding Wheel structure and the resultant Grinding Wheel topography is discussed. The overall objective of the underlying research project was to create a mathematical-generic Grinding Wheel model in which the spatial arrangement of the components grains, bond and pores is simulated in a realistic manner starting from the recipe-dependent volumetric composition of a Grinding Wheel. With this model it is possible to determine the resulting Grinding Wheel structure and the Grinding Wheel topography of vitrified and synthetic resin-bonded CBN Grinding Wheels and thus to predict their application behavior. The originality of the present research results is a generic approach for the modeling of Grinding Wheels, taking into account the entire Grinding Wheel structure and build up the topography based on it. Using original mathematical methods, the components of Grinding Wheels were analyzed and distribution functions of the components were determined. Thus the statistical character of the Grinding Wheel structure was taken into account. In future, the presented model opens new perspectives in order to optimize and to increase the productivity of Grinding processes.
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Modelling of the Grinding Wheel Structure Depending on the Volumetric Composition
Procedia CIRP, 2016Co-Authors: Fritz Klocke, Patrick Mattfeld, Markus Weiß, Sebastian Barth, Karl-heinz Brakhage, Christian Wrobel, Michael RomAbstract:Abstract The volumetric composition of a Grinding Wheel is decisive for its structure and topography properties. However, the application-specific choice of Grinding Wheels is commonly based on experience. To enable a knowledge-based selection of Grinding Wheels, the WZL and the IGPM of the RWTH Aachen University develop a mathematical model in order to simulate the structure and the topography of a Grinding Wheel dependent on its volumetric composition. This paper presents a numerical model, which allows the simulation and display of the Grinding Wheel structure depending on its volumetric composition. Thereby, the grain morphology, the grain size distribution as well as pores and different bonding types are considered. Furthermore, a method to verify the results of the model is introduced and the correlation between the simulation and the real Grinding Wheel structure is shown.
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Mathematical Modeling of Grinding Wheel Structures
2015Co-Authors: Michael Rom, Patrick Mattfeld, Sebastian Barth, Karl-heinz Brakhage, Christian Wrobel, Fritz KlockeAbstract:The proper choice of a Grinding tool is essential for a productive Grinding process and a high quality of the resulting work piece surface. Therefore, the Grinding Wheel structure consisting of abrasive grain material, bonding material and pores has to be composed wisely. Since this process is nearly exclusively based on experience, it can be very expensive and time-consuming. In this work, we present a new approach for mathematically modeling the Grinding Wheel structure with the objective of predicting the volumetric composition of the Grinding Wheel components such that Grinding requirements can be met without using trial and error methods. For the development of a mathematical model, we focus on a small element of a Grinding Wheel, such as a cube, which we call volumetric structure element (VSE). Input parameters like the grain, bond and pore volumes and the distribution of grain sizes and shapes determine the structure of the VSE. The grains can be chosen from convex polyhedrons or from scan data obtained from computer tomography (CT). In the latter case, the grains can be non-convex. The convex polyhedrons can be modified by randomly changing angles and edge lengths and by randomly choosing planes to cut off corners or edges of the polyhedrons. Each grain is represented by a triangle mesh which is generated by applying the quickhull algorithm in the convex case and the marching cubes algorithm with an optional subsequent simplification in the CT case. The grains can be moved collision-free in the VSE to obtain the required grain volume fraction prescribed by the particular Grinding Wheel specification. Therefore, an iterative algorithm incorporating the bounding sphere of each grain is applied. For modeling the Grinding Wheel topography, intersecting planes through the VSE can be calculated. The change of the topography, i.e., of the grains and of the bond, depends on statistical distribution functions for grain fracturing, grain break-out and bond fracturing determined by experiments. Every single grain of the Grinding Wheel surface is then analyzed, e.g., regarding the volume fraction of a grain protruding from the bond. If a critical ratio of that volume fraction to that of the attached bond is exceeded, the grain breaks out.
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Mathematical Modeling of Ceramic-Bonded Grinding Wheel Structures
2015Co-Authors: Michael Rom, Fritz Klocke, Sebastian Barth, Karl-heinz Brakhage, P. Mattfeld, Christian WrobelAbstract:The proper choice of a Grinding tool is essential for a productive Grinding process and a high quality of the resulting work piece surface. Hence, the Grinding Wheel structure consisting of abrasive grain material, bonding material and pores has to be composed wisely. We present a new approach for mathematically modeling such Grinding Wheel structures with the objective of predicting the volumetric composition of the Grinding Wheel components such that Grinding requirements can be met without using trial and error methods. For the model, we focus on a small element of a Grinding Wheel, such as a cube, which we call volumetric structure element (VSE). In this paper, we concentrate on several aspects of the modeling procedure, namely the initial grain arrangement, a collision-free grain rotation and translation algorithm to obtain required grain volume fractions in a VSE, the tetrahedral mesh generation for a whole VSE and the modeling of ceramic bond.
Patrick Mattfeld - One of the best experts on this subject based on the ideXlab platform.
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Influence of different Grinding Wheel and dressing roller specifications on Grinding Wheel wear
Production Engineering, 2018Co-Authors: Sebastian Prinz, Daniel Trauth, Patrick Mattfeld, Fritz KlockeAbstract:A targeted adjustment of the dressing results and the methodological influence of the dressing process on the non-stationary wear of a Grinding Wheel after dressing increases the productivity and the reproducibility of Grinding processes. Despite the great economic importance of Grinding processes with vitrified corundum Grinding Wheels and the great relevance of the dressing process for the application behavior of these Grinding Wheels, quantitative models are missing for the purposeful design of the dressing process. In previous studies, a dressing model was successfully developed which predicts the dressing force in the dressing process as well as the workpiece roughness and the Grinding Wheel wear behavior in a Grinding process for a specific Grinding Wheel and form roller specification. However, a transferability of this model to other Grinding Wheel and form roller specifications is not possible because the influence of the grain size and the hardness of the Grinding Wheel as well as the dressing tool topography on the Grinding Wheel wear and thus on parameters of the dressing model are not known. The objective of this work was to extend the model to additional Grinding Wheel and form roller specifications to ensure a broad applicability of the model.
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DETAILED ANALYSIS AND DESCRIPTION OF Grinding Wheel TOPOGRAPHIES
Journal of Manufacturing Science and Engineering-transactions of The Asme, 2017Co-Authors: Markus Weiß, Fritz Klocke, Sebastian Barth, Matthias Rasim, Patrick MattfeldAbstract:In this paper, an innovative approach for the description of the functional properties of a Grinding Wheel surface is discussed. First, the state of the art in the description of Grinding Wheel topographies is summarized. Furthermore, the fundamentals for a new approach for the quantitative description of Grinding Wheel topographies are provided. In order to analyze the functional properties of a Grinding Wheel's topography depending on its specification, Grinding experiments were carried out. For the experimental investigations vitrified, synthetic resin bonded and electroplated Grinding Wheels with varied compositions were analyzed. During the experiments, the topographies of the investigated Grinding Wheels have been analyzed by means of the topotool in detail. The developed software tool allows a detailed description of the kinematic cutting edges depending on the Grinding process parameters and the Grinding Wheel specification. In addition to the calculation of the number of kinematic cutting edges and the area per cutting edge, a differentiation of the cutting edge areas in normal and tangential areas of the Grinding Wheel's circumferential direction is implemented. Furthermore, the topotool enables to analyze the kinematic cutting edges shape by calculating the angles of the grain in different directions. This enables a detailed analysis and a quantitative comparison of Grinding Wheel topographies related to different Grinding Wheel specifications. In addition, the influence of the dressing process and wear conditions to the Grinding Wheel topography can be evaluated. The new approach allows a better characterization of the contact conditions between Grinding Wheel and workpiece. Hence, the impact of a specific topography on the Grinding process behavior, the generated Grinding energy distribution, and the Grinding result can be revealed.
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Modelling of the Grinding Wheel Structure Depending on the Volumetric Composition
Procedia CIRP, 2016Co-Authors: Fritz Klocke, Patrick Mattfeld, Markus Weiß, Sebastian Barth, Karl-heinz Brakhage, Christian Wrobel, Michael RomAbstract:Abstract The volumetric composition of a Grinding Wheel is decisive for its structure and topography properties. However, the application-specific choice of Grinding Wheels is commonly based on experience. To enable a knowledge-based selection of Grinding Wheels, the WZL and the IGPM of the RWTH Aachen University develop a mathematical model in order to simulate the structure and the topography of a Grinding Wheel dependent on its volumetric composition. This paper presents a numerical model, which allows the simulation and display of the Grinding Wheel structure depending on its volumetric composition. Thereby, the grain morphology, the grain size distribution as well as pores and different bonding types are considered. Furthermore, a method to verify the results of the model is introduced and the correlation between the simulation and the real Grinding Wheel structure is shown.
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Influence of the dressing process on Grinding Wheel wear
Production Engineering, 2015Co-Authors: Fritz Klocke, Janis Thiermann, Patrick MattfeldAbstract:The generation of the Grinding Wheel topography is described in many different models and approaches. These models do not consider the influence of the dressing process on the wear of the Grinding Wheel. In particular the prediction of this wear dependent on the dressing process parameters is not possible with the currently available models. This article describes a novel model for the initial wear of vitrified bonded Grinding Wheels on the basis of Linke’s dressing model. Therefore, the load of the Grinding Wheel in dressing process is depicted using the mean dressing chip cross section, which is then used to model the wear of the Grinding Wheel. An analytical-empirical model for the initial radial Grinding Wheel wear in dependence of the load in dressing process is presented. Furthermore, the influence of the load in the dressing process on the wear mechanisms of the Grinding Wheel, in particular on the relative frequency of the fracture phenomenon grain break-out, is shown. The new model allows the prediction of the wear of the Grinding Wheel as a function of the geometric-kinematic engagement in dressing processes using the mean dressing chip cross section.
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Detailed Analysis and Description of Grinding Wheel Topographies
Volume 1: Processing, 2015Co-Authors: Markus Weiß, Fritz Klocke, Sebastian Barth, Matthias Rasim, Patrick MattfeldAbstract:In this paper, an innovative approach for the description of the functional properties of a Grinding Wheel surface is discussed. First, the state of the art in the description of Grinding Wheel topographies is summarized. Furthermore, the fundamentals for a new approach for the quantitative description of Grinding Wheel topographies are provided. In order to analyze the functional properties of a Grinding Wheel’s topography depending on its specification, Grinding experiments were carried out. For the experimental investigations both vitrified and synthetic resin bonded Grinding Wheels with varied compositions were analyzed.During the experiments, the topographies of the investigated Grinding Wheel surfaces have been analyzed in detail. The developed software tool allows for a detailed description of the kinematic cutting edges depending on the Grinding process parameters and the Grinding Wheel. In addition to the calculation of the number of kinematic cutting edges and the area per cutting edge a differentiation of the cutting edge areas in normal and tangential areas of the Grinding Wheel’s circumferential direction is implemented. This enables a detailed analysis and a quantitative comparison of Grinding Wheel topographies related to different Grinding Wheel specifications. In addition, the influence of the dressing process and wear conditions can be evaluated. The new approach allows a better characterization of the contact conditions between Grinding Wheel and workpiece. Hence, the impact of a specific topography on the Grinding process behavior and the Grinding result can be revealed.Copyright © 2015 by ASME
