Continuous generating grinding: Machine tool optimisation by coupled manufacturing simulation

Continuous generating grinding is a widely established industrial process for the hard finishing of gears. Given the typically dynamic cutting forces, the description of the dynamic behaviour of the machine tool is particularly challenging. Furthermore, manufacturing simulations are numerically complex as the chip forming zone can only be described via the intersection of curved surfaces. This investigation presents a methodology by which the process forces are accurately simulated and aligned with experimental measurements. These forces are coupled with a dynamic multi-body system and form a realistic manufacturing simulation. By this coupled manufacturing simulation, the mechanical structure of a machine tool can be analysed and optimised in relation to the machining process. Conclusions regarding the ground workpiece surface topography are also possible and are used in the overall evaluation. (C) 2016 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.