Finite element simulation of sintering of metal-bonded grinding wheels

Abstract

The grinding wheel properties porosity, particle distribution and the grain holding force influence the surface roughness of the machined workpiece and the performance of the grinding process. These properties of a grinding wheel are in turn defined during tool production. However, the adaptation of the properties of a grinding wheel to the specific grinding task is currently based on empirical knowledge and experience. Understanding the interdependencies from the initial manufacturing to the final grinding results is the key to achieve the target-oriented generation of the grinding wheel properties for the grinding task at hand. With regard to the large number of powder particles for the manufacturing of metal-bonded grinding wheels, an analytical investigation of the powder metallurgical processes is not suitable. Numerical simulations offer a cost and time saving alternative to provide information on the sintering behavior and gain knowledge on the acting mechanism. In this article the sintering of a metal-bonded diamond grinding wheel is modelled and the obtained results are connected to material properties of the resulting grinding layer.