Computer simulation of sub-micron-scale precision truing of a metal-bonded diamond grinding wheel

Abstract

A new simulation mode of wheel profile generation was proposed in precision truing of a metal-bonded diamond grinding wheel by considering the mutual wear of grinding wheel and truer in sub-micron scale. The aim is to understand how truing parameters influence truing accuracy and truing efficiency, namely wheel profile flatness and truing number. In order to assure the sub-micron-scale accuracy of a trued wheel profile, dry electro-contact discharge was employed in arc envelope truing. First, an arc-shaped truing profile replicated on wheel profile was defined and analyzed theoretically and then identified by truing experiment; second, the micro-truing ratio describing the mutual wear of a grinding wheel and truer related to the depth of cut was investigated by micro-truing experiment; then the simulation mode of the truing grinding wheel was established by using dispersed profile coordinates of the grinding wheel and truer with reference to the micro-truing ratio; finally, simulation analysis was conducted to trace on-line formation of the trued wheel profile in truing process. It is confirmed that this simulation method is valid and applicable to visualize the sub-micron-scale truing process. It is also found that by decreasing the depth of cut or plunge truing number wheel profile flatness decreases but truing number increases. It is concluded that there exist minimum wheel profile flatness and minimum truing number in a truing process, which can be used to optimize truing parameters for efficient precision truing.