Abstract
Grinding efficiency and workpiece surface integrity are greatly affected by deflections that occur within the grinding contact zone. This paper is concerned with the effect deflections have on the real length of contact. A new relationship for the contact between the grinding wheel and the surface of the workpiece is introduced based on contact mechanics. The real contact length between the grinding wheel and the workpiece has been modelled based on the theory for cylinders in contact including the effect of the surface roughness of the contact faces. A second formulation is presented which takes account of the contact area at the micro level of the grains. The new model more accurately describes the mechanics of grinding contact than previous contact models. Application of the new model to published experimental data for plunge surface grinding operations explains why measured contact Application length can be 50% - 200% greater than the geometric contact length.
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