An Investigation Into the Grinding Characteristics and Wear Evolution of Micro-Elastic Composite Grinding Pads

Abstract

Abstract This paper introduces a novel micro-elastic composite grinding pad for material removal. The study also developed a new grinding wear formula grounded in microcontact mechanics, which is crucial in examining the evolution of interface characteristics under optimal parameter combinations. The results showed that the material removal rate (MRR), reduction of roughness height (σ), and peak curvature radius (ρ) increase were the highest in the initial stage, followed by a slight increase in the real-contact area in the second stage. This research suggests that abrasive particles primarily detach from the elastic pad in the second stage. The plasticity index (ψ) decreases during grinding, which suggests a transition from an elastic–plastic mixed contact interface to a predominantly elastic contact interface. This shift in the interface mechanics explains the gradual reduction in wear at the grinding interface. Both the plasticity index and the MRR are consistent throughout the grinding process. However, the plasticity index is a more effective index of interface wear than the conventional H/E ratio because it considers the surface roughness’s shape and size, which is essential in mild grinding operations. The findings of this study can be used to improve the design and performance of micro-elastic composite grinding pads and to optimize the grinding process for improved efficiency and sustainability.