Geometric physically-based simulation of microfinishing: tool design impact on workpiece shape

Due to complex interrelations between process configurations, tool characteristics and process results, the design of microfinishing operations is challenging. Microfinishing is often conducted to generate high surface qualities and shape accuracies of highly loaded components. For some applications, e.g. bearing seats, the contact surface is desired to provide a convex shape in order to optimise the contact condition of the bearing ring and the shaft shoulder. In this paper, new models for a geometric physically-based simulation system are presented and applied to predict workpiece topographies and shapes resulting from the use of different tool designs in microfinishing operations. These models include a process-specific force control based on modelling the engagement of single grains, the consideration of the initial tool condition as well as the modelling of wear-related breakouts of individual grains. The developed simulation system was validated by a comparison of the results to experimental investigations.