Surface Grinding Force Modeling And Its Application

Grinding is one of main methods used in the precision and superprecision manufacturing. Grinding force has great influence on the wear of grinding wheel, the deformation of technical system, the surface quality of workpiece, etc. Therefore, it is important to advance a model to predict the grinding force.The progresses on the modeling of grinding process and the gear grinding were analyzed. The research approach is established as follows: Firstly, research on the size effect in grinding process; secondly, deduce a formula for calculating the grinding force in surface grinding; lastly, advance a formula for calculating the grinding force in gear grinding combined with the principle of gear grinding.The advancement on the size effect in grinding process was studied. The specific grinding energy is divided into the specific cutting energy and the specific sliding energy. And those two specific energies were analyzed, respectively. The explanations to the size effect in grinding process are proposed.A new mathematical model of the grinding forces, which are composed of chip formation force and sliding force, in surface grinding is proposed. The comparison of the experiments and the calculations proves the effectiveness of the model. It is proposed that the chip formation energy is divided into the static chip formation energy and the dynamic chip formation energy. The dynamic chip formation energy is influenced by the shear strain, the shear strain rate and the heat in the metal removing process. A formula for calculating the chip formation force is given by analyzing the relationship between the chip formation energy and the chip formation force. And a formula for calculating the sliding force considering the influence of technologic parameters on friction coefficient is proposed based on the achievements of other researchers.The geometrical model of the gear grinding process was established. And the geometrical shape of the metal material, which was cut from the gear in any stroke of the cone-shaped grinding wheel, was calculated. A formula for calculating the grinding force in gear grinding process was obtained by integrating the formula for calculating the grinding force in surface grinding along the direction of the grinding width.