Modeling a Cylindrical Surface Machined by a Non-circular Face Tool

Abstract

The model is generated on the basis of representing a single arbitrarily shaped abrasive grain as a set of separate cutting elements having different conditions of contact with the machined surface. The type of contact with the workpiece surface is determined for each point of a set; such contact types are cutting, deformation, or no contact. The model allows to predict the roughness parameters of the machined surface as well as to determine the characteristics of the contact with the mating one.Surface topography has a significant impact on its operating performance, in particular on wear resistance. A surface with intersected type of lay has the highest wear resistance. To obtain such a micro-relief on the cylindrical surface, a disc-shaped abrasive tool with a non-circular socket working layer is designed. Such a tool has ample opportunities to shape cylindrical surface micro-relief of various directions. Furthermore, such an abrasive tool operates under the conditions of a quasi-discrete contact, which reduces the temperature in the cutting area and thereby increases the machining efficiency.