Design simulation of modular abrasive tool

Abstract

Introduction. Grinding is one of the most common types of finishing. It allows the production of surfaces with the required quality parameters and is one of the most available and productive methods for machining high-strength and difficult-to-machine materials. Grinding wheels represent the most prevalent application of grinding technology in mechanical engineering. The use of this abrasive tool helps to increase processing productivity by ensuring the removal of a significant layer of material. In addition, grinding wheels have a longer service life and are widely used in the implementation of hybrid technologies based on the combination of mechanical (abrasive), electrical, chemical, and thermal effects in various combinations. A variety of tool body shapes and types of abrasives allow the use of wheels in a wide variety of production areas. One of the ways to analyze and design a new tool is numerical simulation. In this research, graphic modeling was selected as the most appropriate method for representing the future design of the tool. This approach allows for a more straightforward conceptualization process compared to other modeling techniques. The purpose of the work is to simulate a modular abrasive tool in order to analyze and synthesize structures to increase the efficiency of tool support for the manufacture of products made of high-strength and difficult-to-process materials using traditional or hybrid processing technologies. Research methodology. Theoretical studies are carried out using the basic principles of system analysis, geometric theory of surface formation, cutting tool design, graph theory, mathematical and computer simulation. To solve the problem, we have studied the available designs of modular grinding wheels. There has also been the analysis of the types of abrasive parts, methods of fastening of the abrasive cutting part on the wheel’s body, the materials used for the manufacture of the body, the characteristics of the body of the wheel, and fastening schemes. Results and discussions. A simulation technique based on graphic modelling theory has been developed. A comprehensive investigation of the existing design of the grinding wheel has enabled the identification of the key structural elements that define its design. The data obtained has been used to create a generalized graphic simulation of a modular abrasive tool. This simulation integrates all the components and displays a conditional constructive relationship between them. The developed design methodology was tested on an example of two designs of modular grinding wheels. The theoretical studies established that the design efficiency of modular abrasive tools can be increased by 2–4 times by using the developed simulation technique.