Modeling and analysis of grinding forces based on the single grit scratch

Abstract

Creating scratch by an abrasive grit is mostly investigated to enhance the finishing processes. The grinding process is such that a number of abrasives with a specific statistical distribution is engaged with the workpiece and performs the material removal. If we can consider the scratching and material removal processes for a single grit indicated on the grinding wheel as a smaller element, then the material removal process could be developed and extended for every engaged abrasive edge in the grinding. In this paper, a new analytical force model for grinding process is developed by modeling abrasive grits and their interaction with the workpiece individually. Grits are examined to determine their geometrical properties and distribution on the grinding wheel. Analytical equations for total normal and tangential force components are established. Especially, the model takes into account the microstructure of the grinding wheel given by the grain geometry and the grain density. Also, the effect of kinematical parameters and process inputs on the forces will be examined. The obtained results showed that the increasing in parameters such as the slope of abrasive grits on the surface of the grinding wheel and the number of active grits on the grinding zone lead to a reduction in forces. The validity of the model can be proved by comparison of experimental results. Modeling forces in the single grit scratch will be a key factor in accurate modeling of the grinding process, and the research findings provide important information for a better understanding of the process.