Modeling and simulation of cutting forces in surface grinding processat micro level using matlab

Abstract

Grinding is a major manufacturing process that accounts for approximately 20 newline25% of total machining expenditures in industrialized countries. Everything used newlinetodayhas been machined by grinding at some point in its manufacturing process or has newlinebeen produced by machines that owe their functionality to grinding operations. newlineGrinding forces play a key role in the grinding process by influencing the specific newlinepower consumption, heat generation at the interface of abrasive cutting grains and the newlineworkpiece, quality of the ground workpiece surface and various other performance newlineparameters. So, a mathematical model to estimate the grinding forces would help to newlineachieve the target. Previously developed models were usually based on the assumption newlinewhich might contradict with the reality as they didn t consider the grain-workpiece newlineinteraction at the micro level (i.e., rubbing, ploughing and cutting). Also, most previous newlinestudies could only be used to predict average values on wheel basis of grinding forces newlinebecause the most models were built based on average grain cutting depth or average newlinechip thickness, and none of the grinding force details at the micro level. newlineA new model to predict the grinding forces at micro levelof grain-workpiece newlineinteraction have been developed in the present study and validated with help of newlineMATLAB and data available in the previous studies. The effects of grinding newlineparameters such as depth of cut, workpiece speed, wheel speed and size of abrasive newlinegrains was studied. The predicted grinding forces were almost identical to the grinding newlineforces experimentally estimated by the previous researchers, with an average newlinepercentage error of 6.09%. It was found that the Size of the abrasive grains (abrasive newlinegrit number) have the largest impact on rubbing, ploughing and cutting contributions. newlineDepths of cut have the second largest effects and the dominant force component could newlineprobably be changed from rubbing to cutting by using different cut depths. The effects newlineof wheel speeds can also be seen: fast wheel speeds lead to less rubbing forces and newlinemore cutting forces, while the effects of workpiece feed rates seem to be limited. newlineTherefore, high wheel speeds and large workpiece feed rates are recommended to newlineachieve high material removal rates. newline