Description of topography of grinded surface during flat grinding with the periphery of a wheel

Abstract

The paper solves the problem of modeling a machined workpiece surface after processing with a grinding wheel during flat grinding with the periphery of the tool. When scaling the simulation of the entire tool and the entire workpiece surface over a long period of processing, the task becomes much more complicated and requires large computational capacities. It is proposed to use spline surfaces when modeling a machined surface. This will allow reducing the computational volume of the solvable problem and implementing a model of this scale. The developed method of modeling of a scratch from single abrasive grain by creation of three guides curves and the forming curve moving on them is described. The suggested method of modeling of a surface of a scratch allows receiving values of depths of each of scratch topography points in the settlement way. The paper experimentally confirms the adequacy of the developed model for describing a single scratch by using specially developed tool design with single abrasive grain. Further, a virtual model of the grinding wheel is built for a transition from a single scratch to a machined surface, taking into account the fractional composition of abrasive grains, visual illustrations of the tool’s surface are given. Further, based on the developed model for describing a grinding scratch in the form of a spline surface and based on the three-dimensional model of the tool, the machined surface of the workpiece is formed. The paper presents a procedure for calculating the roughness parameters for a virtual surface. In conclusion, the simulation results in the model are compared with experimental data and data from other researchers. It is shown that the model has a high accuracy of predicting real roughness parameters in the processes of flat grinding with the periphery of a wheel.