Simulation-Based Prediction of Process Forces for Grinding Free-Formed Surfaces on Machining Centers

During the grinding of hard materials using cylindrically and spherically shaped mounted points - like for the machining of complex forming tools with abrasive-wear-resistant coatings - the process force is an important factor influencing the accuracy of the machining outcome. A simulation-based prediction of these forces could be used to adapt the tool path and, thereby, to keep the grinding forces at a low level. In this paper, a simulation system based on the modeling of each grain of the grinding tool and the validation of this simulation model are presented. (C) 2012 The Authors. Published by Elsevier B. V. Selection and/or peer-review under responsibility of Prof. Eiji Shamoto