Evaluation of Grinding Repair through modeFrontier RSM and Ansys Mechanical

Author(s): 
Riccardo Cenni (SACMI)

CHALLENGE - This study aims at evaluating the effect of grinding repairing operation based on RSM capabilites in modeFRONTIERGrind repair is a method used by SACMI to repair the surface of cast iron structural components when affected by defects like porosities or inclusions. The aim is the creation of a fast, user-friendly analysis to replace standard methods to improve productivity of SACMI Imola S.C. Ceramic Engineering Department.

SOLUTION - Two different parametric models have been built in order to consider two different geometric topologies in the same project and to fill the whole grinding tool field of application. modeFRONTIER was chosen to manage the RSM (Response surface methodology), Ansys Mechanical to compute the FEM analysis, and a Microsoft Excel algorithm to compute fatigue analysis. The proposed flowchart reduces to one simple and fast step which appears to the user as an excel GUI.

BENEFITS - The complete tool based on modeFRONTIER's RSM capabilities has been validated with a comparison between its results and ones obtained with the standard grinding evaluation workflow for a set of cases. All tests gave a results within a +/-5% band respect to the reference results. The tool is currently used in SACMI, resulting in reduction of human worktime. 

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