Effects of the Impacting Velocity and Angle on the Grinding Force, Force Ratio and Deformation Behavior During High-shear and Low-pressure Grinding

Abstract

Background: Background: The normal grinding force is generally larger than the tangential one during conventional grinding processes. Consequently, several machining issues arise, such as a low material removal rate, a high grinding temperature, and poor surface integrity. To overcome the constraints associated with conventional grinding methods, a novel “high-shear and low-pressure” flexible grinding wheel is utilized. A thorough investigation of the influence of machining parameters on the highshear and low-pressure grinding performance from a microscopic perspective is focused. Objective: The effect of the impacting angle and velocity on the grinding force, grinding force ratio, and fiber deformation displacement is explored at the microscopic level. Methods: An impact model was established using ABAQUS software to explore and analyze the interaction results of micro-convex peaks with the abrasive layer under different processing conditions. Results: It was found that the normal grinding force Fn increased with both impact angle and velocity. Similarly, the tangential grinding force Ft is enhanced with increasing velocity. However, its magnitude is reduced with impact angle. Conclusion: The grinding force ratio is primarily affected by the impact angle, which displays a declining trend. The maximum fabric deformation displacement reaches 72.4 nm at an angle of 60° and at a velocity of 9 m/s.