Modeling and simulation of high-speed cylindrical grinding based on 3D grinding wheel topography

Abstract

The purpose of this paper is to establish a 3D virtual grinding wheel to illustrate the high-speed cylindrical grinding process of difficult-to-machine materials under various process parameters. Based on Monte Carlo method, the abrasive grain is modeled cutting spherical solid with random planes, and the random distribution of grains is obtained based on the virtual grid method. Then the grinding wheel topography is trimmed to adjust the protrusion height of abrasive grains. The simulations of high-speed cylindrical grinding under different grinding conditions are carried out considering the thermomechanical coupling effect of grinding wheel and workpiece. The 3D grinding wheel is validated by analyzing the grinding force ratio. The effects of cutting depth on the grinding performance, such as grinding force, workpiece temperature, effective stress and surface quality, are discussed. The results show that a smaller depth of grinding is beneficial for better surface quality.