Nonlinear process machine interaction in tool grinding

The manufacturing of high performance cutting tools, like drills and chamfers, is done by a deep grinding process. This tool grinding process shows nonlinear relations between predefined process parameters, as cutting depth, feed speed and cutting speed, and the process characteristics, as process forces, surface properties and stability. Within an interdisciplinary research project a process model is built up to represent the process machine interaction and to predict process forces, deformation of the workpiece and geometry errors caused by this deformation. In this paper, the process model and the coupling of the included submodules will be described. The focus is thereby on the explanation of the contact module and the implementation in the dynamical model. (© 2011 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)