Study on brittle material removal in the grinding process utilizing theoretical analysis and numerical simulation

Abstract

In this article, the material removal volume (MRV) of single abrasive grain in a rotational period and material removal rate (MRR) in the grinding process of brittle materials are investigated by theoretical analysis and numerical simulation. The results of numerical simulation are consistent with those of theoretical analysis, which indicates that the present numerical method is reasonable. The study focuses on the effects of wheel speed, grinding depth, apex angle of abrasive grain, and workpiece feed rate on the MRV/MRR and grinding force. It shows that the material removal is mainly in brittle mode and the ground workpiece surface is scratched out a groove with a certain width by abrasive grain. A high wheel speed is able to enhance the MRR; however, when wheel speed increases to a certain value, its effect on MRR is not distinct. The MRV and MRR are increment with the increasing grinding depth or apex angle of abrasive grain. The workpiece feed rate has a little influence on MRV/MRR and is weaker than wheel speed, grinding depth, and apex angle of abrasive grain. The grinding force versus the four parameters has a similar trend with MRV meaning that it is one of the major factors influencing material removal.