A meta-model framework for grinding simulation

When considering the mechanics of grinding, several physical phenomena have to be modeled, each one having effect on the resulting grinding forces, wheel and workpiece geometry. Depending on the analyzed problem, some dependencies can be neglected to privilege some aspects instead of others. Nevertheless, all models essentially start considering wheel-workpiece engagement and the corresponding material removal (both wheel and workpiece side), deriving the forces by means of energy balances and/or shear mechanics. The meta-model proposed in this paper represents a general framework conceived for providing a time-domain simulation engine based on a dexel representation of wheel and workpiece, capable to “host” all the semi-empirical models existing in literature, where the overall grinding force is the result of the integration of the force contributions associated to the local removal along wheel-workpiece engagement arc. A cascade approach is adopted to solve for forces and displacements the DAEs set describing the dynamic interactions between wheel and workpiece, whereas all the algebraic relationships pertaining to the various specific models are solved in a pre-processing phase, yielding a set of response surfaces that are queried during time integration. Finally, the meta-model framework is instantiated for a model of traverse roll grinding with force-dependent wheel wear.