RPM-Synchronous Grinding: An Innovative and Efficient Manufacturing Method for the Production of Non-Circular Workpieces

Abstract RPM-Synchronous Grinding (RSG) opens up a wide range of applications, as this manufacturing process enables the efficient production of components with a functional macro geometry as well as a functional micro geometry of the surface. Unlike conventional non-circular grinding approaches, the RSG process strategy requires no oscillation of the infeed axis of the grinding spindle generated by coupling the rotation with the workpiece spindle. By using a fixed ratio of grinding wheel and workpiece spindle speed in conjunction with a non-circular grinding wheel geometry, almost all workpiece macro geometries can be produced in a simple plunge grinding process. The topology of the grinding wheel, the kinematic parameters of the dressing and grinding process and the material parameters of the workpiece must be sensibly matched to each other for an advantageous application of the process. Experiments can help to identify relationships, but simulation tools are needed to derive general predictions. Therefore, Molecular Dynamics Simulation (MD) is used to analyze the material removal process. By considering synchronous grinding at this level, the microstructural development of the workpiece and the chip formation process follow directly from atomic interactions, thus yielding elementary relationships to describe grinding. In the presented application, a defined cam geometry for an established steel material is produced using a conventional vitrified grinding wheel in the RSG process. The surface quality and geometric accuracy of the manufactured workpieces are evaluated. A selection of the MD grinding simulation results (workpiece, abrasive, and their interactions) is presented, and their intended application to the grinding process is discussed.