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A multi-scale model revealed in the grinding process and its influence on the grinding force and surface integrity

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Abstract

The quality of ground surface is closely related with the interaction behavior between the ground component and the grains in grinding wheel. Normally, the grains have the characteristics of irregular shape, nonuniform size and random distribution. Thus, the material removal mechanism generated from the interaction behavior in grinding is difficult to directly observe through experiment. This research presents a multi-scale model to capture the interaction state of the grain-workpiece by determining the transient stage of each individual grain based on the actual grinding wheel structure and grinding condition. Different from the previous models of the single-grain grinding, it provides a fresh perspective to theoretically improve the quality of ground surface by incorporating the multi-scale interactive behavior, active transition, and continuous evolution of the grain-workpiece during the grinding process. The predicted forces are compared with the experimental data performed in the research, and also with those in literature. It shows that the maximum error is less than 14%. The proposed model enables it possible to address the multiple effects of grinding parameters, grain size, grain location, and distribution on the transient stage of the active grains in the grinding zone. Therefore, based on the proposed multi-scale model, the innovative approach is revealed to improve the quality of ground surface by modifying the interaction state of the grain-workpiece through the analytical analysis of multi-level parameters related with grinding wheel structure and grinding process.

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Funding

This research was supported by Xueping Zhang from the National Natural Science Foundation of China under the project No. 52075335 and No. 51675339.

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Authors and Affiliations

  1. School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Xin Li, Xueping Zhang & Zhenqiang Yao

  2. Department of Integrated Systems Engineering, The Ohio State University, Columbus, OH, 43210, USA

    Rajiv Shivpuri

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  1. Xin Li
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Contributions

Xueping Zhang is responsible for ensuring that the descriptions are accurate and agreed by all authors. The role(s) of all authors are listed as follows:

Conceptualization: Xueping Zhang and Xin Li

Methodology: Xin Li and Xueping Zhang

Modeling based on software: Xin Li

Validation: Xin Li

Formal analysis: Xin Li and Xueping Zhang

Investigation: Xin Li and Xueping Zhang

Resources: Xueping Zhang and Zhenqiang Yao

Data curation: Xin Li

Writing of original draft: Xin Li

Writing including review and editing: Xueping Zhang

Visualization: Xin Li and Xueping Zhang

Supervision: Xueping Zhang, Rajiv Shivpuri, and Zhenqiang Yao

Project administration: Xueping Zhang and Rajiv Shivpuri

Funding acquisition: Xueping Zhang and Rajiv Shivpuri

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Correspondence to Xueping Zhang.

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We are submitting our original paper to the The International Journal of Advanced Manufacturing Technology. This paper is our original work, and all authors give consent for publication.

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Li, X., Zhang, X., Shivpuri, R. et al. A multi-scale model revealed in the grinding process and its influence on the grinding force and surface integrity. Int J Adv Manuf Technol 130, 2811–2832 (2024). https://doi.org/10.1007/s00170-023-12739-6

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