Thermo-Energetic Design of Machine Tools – Energy Model for Grinding Processes (SFB/TR96)

 

A large part of the cutting energy introduced into the grinding process is converted into heat. The resulting heat is distributed over the components tool, workpiece, cooling lubricant and chips. Depending on the design of these components, the cooling lubricant strategy and the process control, the size and distribution of the energy flows vary and thus influence the thermo-elastic displacement of the machine structure during grinding. During grinding, the workpiece material is machined by the many irregularly shaped, stochastically arranged abrasive grains on the grinding wheel topography and is therefore very complex. For this reason, the energy conversion and heat flow distribution in the grinding process has only been insufficiently researched. An exact prediction of the resulting heat flows and temperature fields in the grinding process is therefore not yet possible.

However, the heat flow distribution and the resulting temperature fields in the machining zone are of significant importance for the grinding process. For example, some wear phenomena in the grinding process are directly or indirectly temperature driven. In the workpiece edge zone, material modifications and residual stresses can also occur, which influence the application behaviour and functionality of the component. In the machine tool, the temperature fields and heat flows from the machining zone lead to a thermo-elastic displacement of the machine structure.

The aim of the research project is to develop a parameterized process model to describe the energy flows in the grinding process.