Finite Element Analysis on Single Abrasive Grinding Ti6Al4V Alloy

The paper presents the simulated 3D Finite Element Model (FEM) while grinding the Ti6Al4V alloy using a single abrasive wheel. Grinding simulation was carried out using a Lagrangian finite element based machining model to predict the tangential cutting force, temperature distribution at grinding zone and the effective stress and strain. All simulations were performed according to the cutting conditions designed, using the plane up-grinding. The work piece was considered as typical materials to machine difficulty. As the cutting speed is increased from 15 m/min to 33 m/min at higher feed rate, a maximum value of 750 MPa stress and higher temperature localization to an extent of 900°C at grinding zone were observed.

Simulation of Chip Formation Behavior during Single Diamond Grains Grinding by CEL Method

The grain orientation plays a great important role during single grain grinding. Single grain grinding simulation could offer an insight into the material removal behavior. However, grinding simulation with FE methods has problems arising from large deformations at the chip root and negative rake angles of the grain. In this work, a coupled Eulerian-Lagrangian method (CEL) is used to model the grinding behavior of single diamond grain in different orientations. The influence of the grain orientations on the grinding forces, grinding process (sliding, ploughing and cutting) and critical undeformed chip thickness are analyzed. The force ratio shows great accordance with the analytical calculation data. The simulation results show that the chip generates quickly and the special grinding force is relatively small when the diamond particle is in octahedral orientation (111)-(100). The workpiece material flows to the side and front owing to the pressing of cutting crystal face. The swelling of the material is generated beside the abrasive grain. The range and height of swelling are increased gradually and kept invariant after chip formation. The deformation of workpiece material contacting with grain edge is very severe. Therefore the biggest residual stress appears at the grain edge of the groove.