Abstract: A 3D rotary burrs grinding simulation system is described. By analyzing the structure of rotary burrs 4-axis NC grinding machine tool, rotary burrs grinding motion model is established. The method of axis direction decomposition based on 3D modeling is provided, which includes decomposing rotational part into simple primitive cells by using Visual C++ and OpenGL as the developing tools, and implementing the boolean operation between the part model and a tool sweeping solid dependent on the tool shape and tool trajectory for each tool movement. To use grinding machining simulation analysis of the interference resulted in grinding, main factors range is determined. Security region is identified in order to avoid interference between grinding wheel and the tooth surface, which can be used for guiding production of rotary burrs and improving the quality of grinding.

Abstract: Based on virtual reality technology, a friendly human-computer interaction interface and virtual machining environment were developed by Visual C++ and OpenGL. Considering the inhomogeneity of grain size and randomicity of grain distribution, virtual grinding wheel was modeled by taking ortho-hexahedron as basic shape of abrasive grains and randomly distributes them on the wheel base. Mathematic model of interference between abrasive grain and workpiece was established. By using the virtual grinding wheel modeled, surface grinding processes with different machining parameters were simulated. The simulation results show that the system could make operators have a further understanding to chip formation, and the machining results could reflect realistic surface topography of workpiece. Complex grinding process can be realistically simulated. It provides visualization models for the research of grinding mechanism and production forecast.

Abstract: The mechanical design of computerized glove machine was traditional. It was not only lack of theoretical analysis of key institutions, but running stability needed to be improved. We analyzed the impact of the needle and cams which was based on the computerized glove machine’s knitting theory and key process points. On the basis of SolidWorks, 3-D model of computerized glove machine’s knitting element was created; We imported the 3-D model to ANSYS/LS-DYNA system and realized the motion simulation of needle and cams. As a result, we got the curves of needle’s displacement, velocity and acceleration. According to the simulation parameters of needle’s movement, the knitting element was optimized design. The result reveals that acceleration reaches a maximum of 0.63×10⁵m/s² when knitting time is 0.052ms. It reduces nearly 16% compare to the result before design optimization of knitting element. The smooth of computerized glove machine is being improved significantly.

Abstract: This paper presents a surface generation mechanism of grinding that captures the microscopic interaction between the abrasive grains and work-surface. The mechanism utilizes both deterministic and stochastic formulations and deals with such realistic constraints as loss/wear and uneven distribution of abrasive grains, roughness of already-ground work-surface, and machine stiffness. Apart from the theoretical treatments, numerical examples are cited showing how the topography of the work-surface evolves because of the proposed mechanism. The work will help build computerized systems ensuring a reliable prediction of the surface roughness due to grinding under the realistic constraints.

Abstract: Visualization of work surface topography through simulations is very challenging task in grinding process due to the complexity of wheel-work interactions with a very high number of cutting points (grits). Kinematic mapping of abrasive grits on a three-dimensional wheel topography enables the evaluation of ground surface topography through simulations. In this paper, a method for generating the ground surface topography based on wheel specifications is presented. Abrasive grits size, abrasives volume percentage and their nature of distribution on the wheel surface are considered in the modeling and visualization of wheel topography. The simulation results of ground surface topographies prove the feasibility of the developed method.