Optimization of the Dynamic Behavior of Grinding Wheels for Grinding of Hard and Brittle Materials Using the Finite Element Method

Abstract In grinding of hard and brittle materials such as advanced ceramics or hard metal, process behavior and work result are closely connected with material removal mechanisms. Material removal mechanisms are determined by complex interactions between material properties, geometry of the grits, the kinematics of grit engagements and the mechanical and thermal loads acting on workpiece and tool due to energy transformation in the grinding process. Experimental investigations of surface grinding processes show that material removal mechanisms are also influenced by dynamic conditions in the contact zone. These dynamic conditions, that are not chatter vibrations, can have both a positive and negative influence on surface quality, process forces and wear of the grinding wheel. For a given machine tool and workpiece the dynamic contact zone conditions can be optimized by the dynamic properties of the hub of the grinding wheel. For analyzing the dynamic contact zone conditions based on the behavior of the grinding wheel the finite element method is used. By means of these analyses the dynamic properties of grinding wheels can be adapted to meet the requirements of a determined grinding process with regard to tool wear, surface roughness of the workpiece and process forces.