Elucidating wear evolution and its impact on material removal via modeling for curved surface belt grinding with pyramid-structured abrasives

Abstract

This study develops a modeling approach to characterize contour accuracy degradation caused by cumulative wear during the grinding of complex curved surfaces with pyramid-structured abrasive belts. Wear area ratio (Rat) is proposed, integrating Hertz contact theory and the Archard wear model to establish a time-varying wear height and material removal model. The model reveals that material removal depth (MRD) exhibits an inverse surface profile distribution across the half contact width under continuous wear, with diminishing center-edge differences over time. Experimental validation confirms that considering Rat, the prediction accuracy increases, with the contour accuracy controlled within ±0.01 mm along the feed direction and fluctuating within ±0.05 mm in the vertical direction. Additionally, the experiments confirmed that MRD and MRR followed an approximate t^−2/3 power, while the Rat values increased with time following a t^2/9 power.