Theoretical modeling and experimental study on grinding force of straight groove structured grinding wheel

Abstract Structured grinding wheel has obvious advantages in reducing grinding force, and the structural parameters of grinding wheel have important influence on the reduction effect of grinding force. In order to determine the influence law of structural parameters on grinding force, the following theoretical modeling and experimental research work are carried out in this paper. Firstly, single grit scratching experiments of the workpiece material are carried out to determine the critical cutting depth for ploughing and cutting transition. The influences of structural parameters on the maximum undeformed chip thickness and the average contact arc length during grinding are analyzed in detail. The abrasive grains are simplified into a cone with a cone apex angle of 120 degrees, the surface topography model of the structured grinding wheel is established according to the measured results of the distribution law of abrasive grains on the surface of the grinding wheel and the structural characteristic parameters. Combined with the grinding force model of single abrasive grain in ploughing and cutting stages, the calculation model of grinding force in the grinding process of straight groove structured grinding wheel is established. Finally, grinding experiments are carried out to verify the accuracy of the theoretical grinding force model. The results show that the calculated values of grinding force are in good agreement with the experimental values, and the maximum calculation errors of tangential grinding force and normal grinding force are 14.5% and 11.8%, respectively. It is found that when the intermittent ratio of structured grinding wheel is constant, the groove width has little influence on grinding force. However, when the groove width is constant, the intermittent ratio has a great influence on the grinding force, and with the increase of the intermittent ratio, the grinding force decreases obviously.