Prediction of Grinding Force by an Electroplated Grinding Wheel with Orderly-Micro-Grooves

Abstract The ability to predict a grinding force is important to control, monitor, and optimize the grinding process. Few theoretical models were developed to predict grinding forces when a structured wheel was used in a grinding process. This paper aimed to establish a single-grit cutting force model to predict the ploughing, friction and cutting forces in a grinding process. It took into the consideration of actual topography of the grinding wheel, and a theoretical grinding force model for grinding hardened AISI 52100 by the wheel with orderly-micro-grooves was proposed. The model was innovative in the sense that it represented the random thickness of undeformed chips by a probabilistic expression, and it reflected the microstructure characteristics of the structured wheel explicitly. Note that the microstructure depended on the randomness of the protruding heights and distribution density of the grits over the wheel. The proposed force prediction model was validated by surface grinding experiments, and the results showed (1) a good agreement of the predicted and measured forces and (2) a good agreement of the changes of the grinding forces along with the changes of grinding parameters in the prediction model and experiments. This research proposed a theoretical grinding force model of an electroplated grinding wheel with orderly-micro-grooves which is accurate, reliable and effective in predicting grinding forces.