A New Model for Grinding Force Prediction and Analysis

In the present paper a new grinding force model is developed by incorporating the effects of variable coefficient of friction and ploughing force. This is based on the fact that chip formation during grinding consists of three stages: ploughing, cutting and rubbing. Equations for the total normal and tangential force components per unit width of the grinding, during these three stages, were established. These components were expressed in terms of the experimental coefficients and process parameters like wheel speed, table feed and depth of cut. All the coefficients were determined experimentally by performing grinding tests at specified conditions. The variation of the friction coefficient with process parameters such as wheel speed and work feed has been taken into consideration while calculating the frictional force components. The ploughing force components were modelled by performing single-grit tests. During these tests the grinding forces were measured by duplicating the cutting mechanism of grinding wheel using a dummy aluminium wheel and a diamond indenter. The predicted normal and tangential grinding forces were compared with those experimentally obtained and the results show reasonable agreement quantitatively. From the total force values the contributions of each component of force were obtained.