Modelling of ceramic grinding processes Part I. Number of cutting points and grinding forces per grit

Abstract

Modelling is necessary for the optimization and control of any process to achieve improved product quality, high productivity and low cost. Of most importance in ceramic grindings is the establishment of process models that relates flexure strength of ground ceramics with wheel specifications, grinding conditions and material properties through consideration of mechanical and thermal interactions between the abrasive grits and the ceramic material and the induced microcracks and residual stresses. As the first effort of the author's research in this direction, this paper evaluates several theoretical equations for the calculation of the number of active cutting points per unit area based on a simulation analysis. Along with the force data obtained from ceramic grinding experiments, the number of active cutting points is used to calculate the average normal and tangential grinding forces per grit, φ n and φ t. Both φ n and φ t are found to be a power function of the average cross-sectional area of the cutting edges or the grit depth of cut. Different expressions for φ n and φ t are found for the predominant ductile-flow regime and the predominant brittle-fracture regime.