Establishment and Verification of the Cutting Grinding Force Model for the Disc Wheel Based on Piezoelectric Sensors

In this paper, a new model of cutting grinding force for disc wheels is presented. Initially, it was proposed that the grinding cutting force was formed by the grinding force and cutting force in combination. Considering the single-grit morphology, the single-grit average grinding depth, the effective number of grits, and the contact arc length between the grit and the workpiece comprehensively, the grinding force model and the cutting force model were established, respectively. Then, a universal grinding cutting force model was optimized by introducing the effective grit coefficient model, dependent on the probability statistical method and the grit height coefficient model with Rayleigh’s distribution theory. Finally, according to the different proportions of the grinding force and cutting force, the grinding cutting force model, with multi-particles, was established. Simulation and experimental results based on piezoelectric sensors showed that the proposed model could predict the intermittent grinding cutting force well. Moreover, the inclusion of the grit height coefficient and the effective grits number coefficient improved the modeling accuracy. The error between the simulation and experimental findings in grinding cutting force was reduced to 7.8% in comparison with the traditional model. In addition, the grinding cutting force can be divided into three segments; increasing, steadiness, and decreasing, respectively found through modeling.

A New Grinding Force Model for Micro Grinding RB-SiC Ceramic with Grinding Wheel Topography as an Input

The ability to predict the grinding force for hard and brittle materials is important to optimize and control the grinding process. However, it is a difficult task to establish a comprehensive grinding force model that takes into account the brittle fracture, grinding conditions, and random distribution of the grinding wheel topography. Therefore, this study developed a new grinding force model for micro-grinding of reaction-bonded silicon carbide (RB-SiC) ceramics. First, the grinding force components and grinding trajectory were analysed based on the critical depth of rubbing, ploughing, and brittle fracture. Afterwards, the corresponding individual grain force were established and the total grinding force was derived through incorporating the single grain force with dynamic cutting grains. Finally, a series of calibration and validation experiments were conducted to obtain the empirical coefficient and verify the accuracy of the model. It was found that ploughing and fracture were the dominate removal modes, which illustrate that the force components decomposed are correct. Furthermore, the values predicted according to the proposed model are consistent with the experimental data, with the average deviation of 6.793% and 8.926% for the normal and tangential force, respectively. This suggests that the proposed model is acceptable and can be used to simulate the grinding force for RB-SiC ceramics in practice.

Investigation on the Grinding Force, Power and Heat Flux Distributions Along the Tooth Profile in Form Grinding of Gears

This paper investigates the distributions of grinding force, power consumption and heat flux along the tooth profile in precision form grinding of gears. A semi-analytical grinding force model has been established considering the static and dynamic chip formation forces and also the sliding force. Variation of the local contact conditions between the wheel and gear flank along the gear tooth profile, including the local depth of cut, local wheel diameter, local wheel speed and also the equivalent wheel diameter has been analyzed. Combining the variation of local contact conditions with the semi-analytical grinding force model, the grinding force and power distributions along the gear tooth profile have been derived. The predicted values of grinding power under different wheel speeds, worktable speeds, radial grinding depths and different contact widths are compared with those experimentally obtained and the results show a reasonable agreement. The predicted grinding forces at different rolling angle positions under different grinding parameters show a good agreement when compared with those experimentally obtained. The heat flux distribution along the interface between the form grinding wheel and the gear flank in form gear grinding has been further calculated.