Process Machine Interaction in Pendulum and Speed-Stroke Grinding

The complex interaction of process forces and machine structure affects the quality of ground workpieces, especially in highly-productive machining processes, if machines are operated at their limits. In speed-stroke grinding, the highly-dynamic process forces are caused by high workpiece velocities and high acceleration of the machine table. These forces are influenced by the process parameters, the material properties, the coolant application and the grinding tool specification. The paper describes the approach to simulate the process machine interaction in speed-stroke grinding by a coupled model. The machine is modeled by a multi-body simulation, which can depict the static and dynamic behavior of the machine for every working position. This machine model is coupled with an analytical-empirical force model, which predicts the process forces regarding the process parameters, the coolant application and the workpiece material. The machine control system is implemented in the model as well. The ability to model a speed stroke grinding process, including the machine, the control system and the process itself can be used to predict and improve the workpiece quality regarding the measurement accuracy minimizing time and cost intensive experiments.