Simulation of the stock removal in the contact zone during internal grinding of brittle non-metallic materials

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Introduction. Finishing operations, in particular, cylindrical grinding, essentially form the quality parameters of products, its performance characteristics and functional suitability. At the same time, the cost of grinding work increases significantly in comparison with grinding metals, reaching an average of 20 ... 28% of the total cost of manufacturing products. The selection of the optimal parameters of the technological system based on the process simulation can improve the reliability, productivity and economic efficiency. To describe the processing of brittle nonmetallic materials, empirical dependences are mainly used, and the existing analytical models do not take into account the stochastic nature of the grinding operation and the combination of microcutting and brittle chipping when removing particles of brittle nonmetallic material and wear of the surface of the grinding tool. Purpose of the work: simulation of stock removal in the contact zone during internal grinding of brittle non-metallic materials. The task is to study the features and patterns of change in the probability of material removal when the treated surface comes into contact with an abrasive tool. In the work, the theoretical and probabilistic models are obtained, allowing to reveal the patterns of material removal in the contact zone. The models make it possible to trace the regularities of the interaction of cutting and piercing grains on the surface of the workpiece and the process of removing the allowance in the contact zone due to a combination of the phenomena of microcutting and brittle chipping, considered as a random event. The research methods are mathematical and physical simulation using the basic provisions of the theory of probability, the laws of distribution of random variables, as well as the theory of cutting and the theory of a deformable solid. Results and discussion. Data are obtained that provide a clear illustration of the patterns of material removal along the contact zone at various levels. Analysis of the results obtained shows that the peripheral speed of the tool and the rotation speed of the workpiece, which are directly included in the equation for calculating the probability of material removal, significantly affect the rate of material removal. The cross feed also has a significant effect on stock removal. A qualitative picture of the change in the probability of material removal in the contact zone during grinding of holes in brittle nonmetallic materials is obtained. The obtained patterns of change in the probability of material removal when the machined surface is in contact with an abrasive tool and analytical dependences are valid for a wide range of grinding modes, tool characteristics and other technological factors.

About the authors

S. M. Bratan

Email: serg.bratan@gmail.com
D.Sc. (Engineering), Professor, Sevastopol State University, 33 Universitetskaya str., Sevastopol, 299053, Russian Federation, serg.bratan@gmail.com

S. I. Roshchupkin

Email: st.roshchupkin@yandex.ru
Ph.D. (Engineering), Associate Professor, Sevastopol State University, 33 Universitetskaya str., Sevastopol, 299053, Russian Federation, st.roshchupkin@yandex.ru

A. O. Kharchenko

Email: khao@list.ru
Ph.D. (Engineering), Professor, Sevastopol State University, 33 Universitetskaya str., Sevastopol, 299053, Russian Federation, khao@list.ru

A. S. Chasovitina

Email: nastya.chasovitina@mail.ru
Sevastopol State University, 33 Universitetskaya str., Sevastopol, 299053, Russian Federation, nastya.chasovitina@mail.ru

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