Research Papers

Modeling and Simulation of Mold and Die Grinding

[+] Author and Article Information
Changsheng Guo

 Physical Science Department, United Technologies Research Center, East Hartford, CT 06118Guoc@utrc.utc.com

J. Manuf. Sci. Eng 134(4), 041007 (Jul 18, 2012) (4 pages) doi:10.1115/1.4006970 History: Received August 11, 2011; Revised March 29, 2012; Published July 18, 2012; Online July 18, 2012

Complex molds and dies often need grinding to achieve the required surface finishes and tolerances. Due to complex part geometry and multiple-axis motion, the wheel–workpiece engagement conditions may vary drastically during grinding, which imposes challenges to choose the appropriate workspeeds. This paper presents a modeling approach to optimize mold and die grinding to reduce cycle time while maintaining process parameters such as grinding force and specific removal rate below critical limits. The wheel–workpiece engagement conditions are calculated for each grinding step by processing the NC program, part and wheel geometries. Grinding forces, power, and temperature are calculated and used as decision variables to optimize workspeed to reduce cycle time. Results for grinding a half bottle shaped mold show that the grinding process parameters vary significantly along the wheel axis at any instant and along the grinding path. The grinding process is far from optimum if a constant workspeed is used. Model-based optimization has been shown to reduce cycle time by 50% while achieving much lower grinding forces and power.

Copyright © 2012 by American Society of Mechanical Engineers
Topics: Grinding , Modeling , Wheels
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Figure 1

Illustration of mold cavity grinding

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Figure 2

Illustration of feed distribution due to tool tilt

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Figure 3

Illustration of wheel–workpiece contact

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Figure 4

Illustration of grinding an inclined surface

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Figure 5

Finish-grinding of bottle-shaped mold cavity

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Figure 6

Specific removal rate versus machining step

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Figure 7

Specific material removal rate

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Figure 8

Wheel–workpiece contact at step 200 (unit in mm)

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Figure 9

Wheel–workpiece contact at step 288 (unit in mm)

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Figure 10

Predicted process parameters

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Figure 11

Optimized process parameters




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