Abstract
In the research on grinding process modeling, the stochastic nature of grain sizes and locations need to be considered. A new numerical model was developed which will describe the micro-interacting situations between grains and workpiece material in grinding contact zone. The model was established based on a series of reasonable assumptions, the critical conditions of starting points of plowing and cutting stages, and the redefined grinding contact zone. It indicated that there are four types of grain existing in grinding contact zone: uncontact, sliding, plowing, and cutting grains. The number of grains per unit wheel volume (N v ) and the undeformed chip thickness (h cu,max), which are key parameters in grinding process modeling, were firstly obtained. The numbers and distributions of different grain types along grinding contact zone were then obtained and analyzed. Calculation results showed that only a small fraction of grains participate in cutting interactions and the changing laws of each grain types along grinding contact length are very different from each other, which gives a deeper insight into grinding process and can be a good foundation for more precise grinding force prediction and thermal analysis. Another important application of this model is for ground surface roughness prediction and a new method on this purpose was developed. At last, two comparisons were made between calculation results and existing experimental data for validating the work on paper. Comparison results showed that the roughness of ground surface can be well predicted and gave the method theoretically to reduce ground surface roughness.
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Jiang, J., Ge, P. & Hong, J. Study on micro-interacting mechanism modeling in grinding process and ground surface roughness prediction. Int J Adv Manuf Technol 67, 1035–1052 (2013). https://doi.org/10.1007/s00170-012-4546-9
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DOI: https://doi.org/10.1007/s00170-012-4546-9