Simulation and verification of arc-enveloping grinding of free-form surface

Simulation method for arc envelope grinding of free-form surface was proposed on AutoCAD software in order to verify 3D formation of ground curve surface and 3D distribution of its form errors concerning tool path planning and wheel wear. First, 3D objects of arc-shaped grinding wheel and workpiece were established in AutoCAD, and then Boolean operation was conducted to simulate arc envelope grinding along tool path by AutoLISP program, finally tool path number and form error were described and analyzed. It can display 3D envelope trace and form error distributed quantitatively on ground curve surface. It was concluded that ground free-form surface becomes smooth when envelope height decreases to a certain extent, and equal-h(e) grinding needs much less tool paths than equal-Delta x grinding especially when envelope height is little and curvature is large and the form accuracy PV is less than 20 mu m responding envelope height of 10 mu m even when wheel radial wear is 1 mm. In addition, grinding experiments proved the validity of the simulation method.