OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 2 4 Design simulation of modular abrasive tool Dmitry Lobanov 1, a, Vadim Skeeba 2, b, Ivan Golyushov 1, c, Valentin Smirnov 1, d, Egor Zverev 2, e 1 I. N. Ulianov Chuvash State University, 15 Moskovsky Prospekt, Cheboksary, 428015, Russian Federation 2 Novosibirsk State Technical University, 20 Prospekt K. Marksa, Novosibirsk, 630073, Russian Federation a https://orcid.org/0000-0002-4273-5107, lobanovdv@list.ru; b https://orcid.org/0000-0002-8242-2295, skeeba_vadim@mail.ru; b https://orcid.org/0000-0001-9757-1368, ivan.golyushov.97@mail.ru; d https://orcid.org/0000-0003-2721-9849, vms53@inbox.ru; e https://orcid.org/0000-0003-4405-6623, zverev@corp.nstu.ru Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2024 vol. 26 no. 2 pp. 158–173 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2024-26.2-158-173 ART I CLE I NFO Article history: Received: 07 March 2024 Revised: 21 March 2024 Accepted: 27 April 2024 Available online: 15 June 2024 Keywords: Abrasive tools Modular grinding wheel Tool design Simulation Funding This research was funded by Russian Science Foundation project N 23-29-00945, https://rscf.ru/en/ project/23-29-00945/ Acknowledgements The research was carried out at the equipment of the Engineering Center “Design and Production of High-Tech Equipment” and the shared research facility” Structure, mechanical and physical properties of materials”. 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. For citation: Lobanov D.V., Skeeba V.Yu., Golyushov I.S., Smirnov V.M., Zverev E.A. Design simulation of modular abrasive tool. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2024, vol. 26, no. 2, pp. 158–173. DOI: 10.17212/1994-6309-2024-26.2-158-173. (In Russian). ______ * Corresponding author Lobanov Dmitry V., D.Sc. (Engineering), Professor I.N. Ulianov Chuvash State University, 15 Moskovsky Prospekt, 428015, Cheboksary, Russian Federation Tel.: + 7 908 303-47-45, e-mail: lobanovdv@list.ru Introduction The quality requirements for products manufactured by machine-building enterprises are increasing every year. This, in turn, leads to the introduction of more traditional and hybrid finishing technologies as well as smoothing ones. Grinding is one of the most common types of finishing used in shaping processes to
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