| Dissertation's language: | German |
| Dissertation's title: | Analyse und Simulation des Prozesses Honräumen von gehärteten Innenprofilen mit Diamantwerkzeugen |
| Diss-Nr.: | 19182 |
| Author: | Guilherme Vargas Evangelista |
| Supervisors: |
K. Wegener N. Schaal R. Schroeter F. Kuster |
| Abstract: |
In this work the basis of hone broaching process is presented, in order to obtain a better understanding of the chip formation at the diamond layer, maximum load limits, wear forms and failure mechanisms as well as a deeper knowledge of the reciprocal effect between work piece and selected process parameters. In this context a method was developed for investigating the chip formation mechanisms on a single diamond grain in hone broaching. This method allowed determining the relationship of the cutting force as a function of grain orientation and cutting angle for a single diamond grain. Based on the Kienzle equation, the specific cutting force and its slope value, considering grain orientation in dependence of the cutting angle, were experimentally determined. A stochastic process model has been developed. It allows the examination of the influence of different process and tool parameters by numeric simulation. The simulation is based on a kinematic-geometrical model and consists of six submodels: tool, kinematic process, material removal, force, deformation and chip space model. The tool model is based on a Monte Carlo method and considers the most important variables of the abrasive surface. The material removal model assumes a kinematic cutting condition. The force model is based on the Kienzle force model for a single grain, while the elasticity of the work piece is considered in the deformation model. The chip space model takes into account the relationship between the chip volume and the chip space. Therefore the simulation reproduces the macroscopic effects of the hone broaching process based on the fundamental microscopic description of single grains and their cutting edges’ engagements. Parallel to the development of the simulation, hone broaching experiments were carried out in order to investigate the effects of different processes and tool parameters on the working forces, surface quality and accuracy. Both, the results of experiments and simulations, led to a better understanding of the hone broaching process. In terms of optimization, a pendulum strategy is proposed, leading to an opportunity for a stronger increase of the economic and operating efficiency of the process. Finally, a proposal for industrial application of the results obtained is presented. |
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| Keywords: | Simulation, Honen, Schleifen |
| Belongs to project: | |
| Date: | 2010/04/27 |