Akintseva A.V., Pereverzev P.P., Degtyareva-Kashutina A.S. Digital twin of a shaping process for a surface of a non-rigid shaft with an elliptical profile processed by plunge grinding

DOI: 10.18503/1995-2732-2021-19-4-98-106

Abstract

Predicting the processing accuracy at the design stage of a CNC grinding operation in digital environment is a currently important task due to the lack of a tool for various CAD manufacturers to monitor control programs for ensuring the specified processing accuracy when manufacturing a batch of parts. To cope with this task, it is proposed to use a digital twin of the shaping process of the machined surface, which makes it possible to predict machining errors by the calculated values of the radii at the end of the cylindrical plunge grinding cycle, taking into account the influence of variable technological factors. This paper presents a model for shaping the radii of the ground surface to calculate the variable depth of cut in all sections of the machined surface at each turn of the workpiece, depending on the compliance of each section of the shaft along the entire length of grinding, taking into account the fluctuations of the allowance and bluntness of the grinding wheel. The introduction of a digital twin contributes to dealing with the task of predicting the processing accuracy at the design stage of a CNC grinding operation. The models presented in the paper are developed by a simulation modeling using analytical methods of mathematical modeling based on fundamental physical laws and basic provisions of cutting mechanics and the theory of plastic deformation of metal in the chip formation zone. Scientific novelty of the studies presented in this paper lies in the development of a digital twin of the shaping process for a machined surface of a non-rigid shaft with an elliptical profile, factoring into the relationship, and influence on the accuracy of machining the depth of cut, cutting conditions, physical and mechanical properties of the metal being processed, cutting force, elastic deformations of the technological system, kinematics of the cylindrical plunge grinding process, geometry of the cutting zone, fluctuations of the allowance, bluntness of the wheel, and variable rigidity of the processed shaft along its length. As a result, the paper presents a part of the novel methodological and mathematical support for the digital twin of the shaping of the processed surface. The industrial use of the digital twin of the shaping of the processed surface is of great practical importance, because it contributes to the automated monitoring of control programs for CNC machines to ensure the achievable processing accuracy, when manufacturing a batch of parts.

Keywords

Cylindrical plunge grinding, digital twin, machining error, shaping process of the machined surface, variable machining conditions.

For citation

Akintseva A.V., Pereverzev P.P., Degtyareva-Kashutina A.S. Digital twin of a shaping process for a surface of a non-rigid shaft with an elliptical profile processed by plunge grinding. Vestnik Magnitogorskogo Gosudarstvennogo Tekhnicheskogo Universiteta im. G.I. Nosova [Vestnik of Nosov Magnitogorsk State Technical University]. 2021, vol. 19, no. 4, pp. 98–106. https://doi.org/10.18503/1995-2732-2021-19-4-98-106

Aleksandra V. Akintseva – PhD (Eng.), Associate Professor of the Department of Engineering, Technology and Construction, South Ural State University, Chelyabinsk, Russia. Email: This email address is being protected from spambots. You need JavaScript enabled to view it.. ORCID 0000-0003-0588-1401

Pavel P. Pereverzev – DrSc (Eng.), Associate Professor, Professor of the Department of the Automated Mechanical Engineering Technology, South Ural State University, Chelyabinsk, Russia. Email: pereverzevpp@ susu.ru. ORCID 0000-0002-1416-8918

Anastasia S. Degtyareva-Kashutina – Senior Lecturer, South Ural State University, Chelyabinsk, Russia. Email: This email address is being protected from spambots. You need JavaScript enabled to view it.. ORCID 0000-0002-4236-9207

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