Grinding process simulation of free-formed WC-Co hard material coated surfaces on machining centers using poisson-disk sampled dexel representations

Deep drawing tools are used in various production processes. In order to increase the life cycle of these tools, thermally sprayed abrasive-wear resistant WC-Co hard material coatings can be applied. With respect to the shape accuracy and surface quality of the forming tools, the coated surfaces have to be finished. A suitable machining process to meet these conditions is grinding on machining centers. In this paper, a geometric simulation model for this grinding process based on the modeling of individual grains with constructive solid geometry techniques is presented. The workpiece is represented by poisson-disk sampled dexels. Validation experiments show a good match of the simulated and measured process forces in different engagement situations.