Dynamical aspects in modeling long cantilevering workpieces in tool grinding

•Introduction of an overall model for dynamical aspects in tool-grinding.•Dynamical workpiece behavior is highly dependent on production stage and clamping.•Finite element description of workpiece with time-variant system matrices.•Increased efficiency of calculation by a combined static and modal reduction.•Results of cutting forces and ground workpiece surface agree well with measurements.

Tool grinding is a complex process in which temporal dynamics of workpiece and grinding wheel, and the material removal process itself, affect the quality of the workpiece. Many existing models already provide the option to study the dynamics of workpiece and grinding wheel or cutting forces and material removal processes, but mostly do not combine these aspects. Here, workpiece dynamics are studied in relation to its structural and geometrical changing properties during machining, and are used to simulate the vibrations and deformation of the workpiece during grinding. In combination with models for the grinding wheel and the material removal process, dependencies of the workpiece dynamics on the workpieces quality are studied and results from this hybrid model are in excellent agreement with empirical measurements. Furthermore, the results demonstrate the significant effects of deformations of the workpiece on its final geometry.