Effects of dressed wheel topography on patterned surface textures and grinding force

Abstract

This paper presents a series of analytical and experimental investigations into the patterning effect of a grinding wheel-dressed surface on workpiece surface texture and grinding forces. An analytical model is built for the profile of the dressing tip and utilized to describe the kinematics of the dressing process on the grinding wheel surface. The model also reflects the ground workpiece surface texture. The model describes patterned surface textures according to ridge width, ridge length, texture angle, and ridge function parameters. Comparison against modeled and measured values strongly suggests that conventional dressing and grinding processes can be pre-determined via the proposed model to generate a patterned workpiece surface. The measured grinding forces are investigated as they relate to tangential and normal components at a series of dressing and grinding parameters; these two components increase dramatically as dressing overlap ratio increases, nearly regardless of dressing depth. Under a given workpiece velocity, the measured forces are much greater at overlap ratio of 6 than at ratios of 1 or 3. There is an average difference of only 5.8% for all grinding forces. Conversely, the measured tangential and normal grinding forces increase markedly as workpiece velocity increases at a specific dressing overlap ratio. Dressing overlap ratio of 1~3 is recommended for generating patterned texture surfaces in a conventional grinding process. Grinding force ratio can serve to monitor the patterned grinding process (error within 12.9%) under the conditions discussed here.