Simulation Based Prediction of Compliance Induced Shape Deviations in Internal Traverse Grinding

Internal traverse grinding (ITG) using electroplated cBN tools in high-speed conditions is a highly efficient manufacturing process for bore machining single axial stroke. However, control difficult. Due to the direction of feed, changes normal force and thus radial deflection tool workpiece spindle system, lead deviations contour along length bore, especially at exit. Simulations including this effect could provide design processes which enhance shape accuracy components. A geometrical physically-based simulation herein developed model influence system compliance on resulting contour. Realistic topographies, obtained from measurements, are combined with an FE-calibrated surrogate forces empirical model. In quasistatic experimental investigations, determined relation acting by piezoelectric measuring elements eddy current sensors. tests in-process measurement technology followed contours, validated. The characteristic predicted good qualitative accordance results.