Z-MAP TECHNIQUE IN GRINDING SIMULATION

Abstract

Due to the simplicity of cutting operation in milling and turning, the z-map, and other techniques were widely used to simulate the interaction between the cutting tool and workpiece in order to define machined surface roughness, chip geometry, cutting force, etc. z-map technique was developed to simulate the interaction between the grains on the grinding wheel and workpiece, and then the uncut chip thickness and contact length, which are the two fundamental parameter that describe the mechanics of grinding, can be obtained from the simulation result The workpiece is represented by a set of evenly spaced lines segment, where the length of each line segment represents the workpiece height. The accuracy of the workpiece representation is determined by the spacing of the lines segment. The simulation program was tested using the following set of data: the grain diameter 0.25 mm, grain spacing 0.42 mm, the wheel diameter 200 mm, the wheel speed 30 m/s, and workpiece speed 0.3 m/s. The depth of cut used for testing was ranged between 0.01 and 0.1 mm. The spacing of the line segments was 1 µm, (1000 line segment per 1 mm).  The simulated results were compared with the analytical results. The differences in the uncut chip thickness and contact length were 1.1%  and 1.4%  for a depth of cut 0.1mm , and 1.0% and 2.1% for a depth of cut of 0.01mm.

Keywords:  Z-map technique; Grinding Simulation; Uncut chip thickness; Contact length