Abstract
Grinding is applied widely in manufacturing of high-precision component. And, pursuing the forming mechanism, together with predicting topography characteristics and roughness of the grinding surface, is becoming more and more important in improving the grinding quality. The grinding surface is formed by the interaction between the grinding wheel and the workpiece. And, its topography is influenced by the grain shape, grinding wheel surface topography, and machining parameters. In this paper, the study started from establishing the topography of wheel surface. And, according to grinding kinematics, the grain trajectory equations were established. By applying the statistical screening methods, the actual cutting depth was determined. Then, the grinding surface topography was formed by simulating. Considering the influence of vibration in actual grinding, the surface topography of the workpiece under forced vibration was studied. The study results showed that the influence of grinding speed was significant for grinding surface topography, mainly in the influence for amplitude and frequency. Finally, the grinding experiments were used to verify the results of the simulation. The obtained experimental results confirmed that the as-proposed method worked efficiently and rapidly in simulating the grinding surface topography and predicting the grinding surface roughness.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
Aurich JC, Braun O, Warnecke G (2003) Development of a superabrasive grinding wheel with defined grain structure using kinematic simulation. CIRP Ann Manuf Tech 52(1):275–280
Cao Y, Guan J, Li B, Chen X, Yang J (2013) Modeling and simulation of grinding surface topography considering wheel vibration. Int J Adv Manuf Technol 66(5-8):937–945
Chakrabarti S, Paul S (2008) Numerical modelling of surface topography in superabrasive grinding. Int J Adv Manuf Technol 39(1-2):29–38
Chen D (2010) Modeling and simulation methodology of the machined surface in ultra-precision grinding. J Mech Eng 46(13):186–191 (in Chinese)
Chen X, Rowe WB (1996) Analysis and simulation of the grinding process. Part I: generation of the grinding wheel surface. Int J Mach Tools Manuf 36(8):871–882
Chen X, Rowe WB, Mills B, Allanson DR (1996) Analysis and simulation of the grinding process. Part III: comparison with experiment. Int J Mach Tools Manuf 36(8):897–906
Huang H, Yin L, Zhou L (2003) High speed grinding of silicon nitride with resin bond diamond wheels. J Mater Process Technol 141(3):329–336
Javidi A, Rieger U, Eichlseder W (2008) The effect of machining on the surface integrity and fatigue life. Int J Fatigue 30(10-11):2050–2055
Jiang JL, Ge PQ, Bi WB, Zhang L, Wang DX, Zhang Y (2013) 2D/3D ground surface topography modeling considering dressing and wear effects in grinding process. Int J Mach Tool Manuf 74(4):29–40
Koshy P, Ives LK, Jahanmir S (1999) Simulation of diamond-ground surfaces. Int J Mach Tool Manuf 39(9):1451–1470
Koshy P, Jain VK, Lal GK (1997) Stochastic simulation approach to modelling diamond wheel topography. Int J Mach Tool Manuf 37(6):751–761
Kruszynski BW, Wojcik R (2001) Residual stress in grinding. J Mater Process Technol 109(3):254–257
Law SS, Wu SM (1973) Simulation study of the grinding process. J Manuf Sci Eng 95(4):972–978
Law SS, Wu SM, Joglekar AM (1973) On building models for the grinding process. J Manuf Sci Eng 95(4):983–991
Li SP, Liang J, Li L, Cao SS, Shu WG, Peng HQ (2003) Study of the ground workpiece surface topography in high-speed precision grinding using a scanning tunneling microscopy. J Mater Process Technol 139(1-3):263–266
Liu PF, Lin B, Yan S, Wang B (2015) Numerical simulation and experimental validation of fixed abrasive grinding pad topography. International Journal of Advanced Manufacturing Technology online:1-12
Liu YM, Warkentin A, Bauer R, Gong YD (2013) Investigation of different grain shapes and dressing to predict surface roughness in grinding using kinematic simulations. Precis Eng 37(3):758–764
Liu X, Zhang B (2002) Effects of grinding process on residual stresses in nanostructured ceramic coatings. J Mater Sci 37(15):3229–3239
Nguyen TA, Butler DL (2005) Simulation of precision grinding process, part 1: generation of the grinding wheel surface. Int J Mach Tool Manuf 45(11):1321–1328
Pinto FW, Vargas GE, Wegener K (2008) Simulation for optimizing grain pattern on engineered grinding tools. CIRP Ann Manuf Tech 57(1):353–356
Qiao G, Dong G, Zhou M (2013) Simulation and assessment of diamond mill grinding wheel topography. Int J Adv Manuf Technol 68(9-12):2085–2093
Shiau TN, Chen KH, Wang FC, Chio CT, Hsu WC (2011) The effect of dynamic behavior on surface roughness of ball screw under the grinding force. Int J Adv Manuf Technol 52(5-8):507–520
Warnecke G, Zitt U (1998) Kinematic simulation for analyzing and predicting high-performance grinding processes. CIRP Ann Manuf Technol 47(1):265–270
Xie Y, Williams JA (1996) The prediction of friction and wear when a soft surface slides against a harder rough surface. Wear 196(1):21–34
Xie J, Xu J, Tang Y, Tamaki J (2008) 3D graphical evaluation of micron-scale protrusion topography of diamond grinding wheel. Int J Mach Tool Manuf 48(11):1254–1260
Zahouani H, Mezghani S, Vargiolu R, Dursapt M (2008) Identification of manufacturing signature by 2D wavelet decomposition. Wear 264(5-6):480–485
Zhou X, Xi F (2002) Modeling and predicting surface roughness of the grinding process. Int J Mach Tool Manuf 42(8):969–977
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Wang, X., Yu, T., Dai, Y. et al. Kinematics modeling and simulating of grinding surface topography considering machining parameters and vibration characteristics. Int J Adv Manuf Technol 87, 2459–2470 (2016). https://doi.org/10.1007/s00170-016-8660-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-016-8660-y