Towards the Prediction of Compliance Influences on Shape Deviations in Internal Traverse Grinding

Abstract

Internal traverse grinding (ITG) with electroplated cBN tools is a highly efficient process for machining of precision bores. Profiled tools allow for high stock removal and good surface quality in a single axial stroke. However, process control is difficult. Especially shape deviations of machined workpieces are influenced by machining system compliances. Simulation-based solutions can be used to predict and compensate shape errors. To model the system compliance, deformations have been measured using eddy current sensors in combination with piezoelectric force measurement components. A simplified substitute model has been developed, which represents the deflections of the entire machining system as a function of the process normal force, and grinding investigations with in-process force measurements have been performed. By incorporating the measured forces and the compliance model into an existing simulation system, the influence on the resulting shape of the bore has been predicted in good accordance with the real grinding process.