Development of specific grinding energy model

Specific grinding energy is one of the most important performance parameter of the grinding process. Primary energy components of specific grinding energy are the major contributors to the total specific energy consumption in grinding. For high strength and hardness materials such as advanced ceramics, specific grinding energy requirement is extremely high which will eventually cause higher material removal cost of such materials. Detailed study of various components of specific grinding energy may help to reduce this energy consumption by appropriate choice of the grinding process parameters. This work studied in detail the four primary components of specific grinding energy namely chip formation energy, primary and second rubbing energy and the specific ploughing energy for two different engineering materials—a ductile mild steel and a hard conductive ceramic. Single grit experiments have been conducted in new and more realistic manner to replicate the actual grinding process and to develop the theoretical models of the specific energy components. Study of specific ploughing energy also helped to explain thoroughly the concept of size effect in grinding.

► Modeling of specific grinding energy for two different materials done.
► New method of single grit scratch test used.
► Four main components of specific grinding energy analyzed.
► Specific ploughing energy found to be most significant component.
► Model helped to explain concept of size effect.