Stochastic modeling of grain wear in geometric physically-based grinding simulations

Grinding processes can be optimized by simulating the influence of individual grains on process forces and surface topographies. However, the process results are significantly influenced by tool wear. Simulating this effect allows, e.g., the prediction of necessary tool changes when manufacturing large forming tools. Therefore, a new point-based approach for modeling arbitrarily shaped grains in different states of tool wear was developed. Based on a small amount of representative wear investigations, a flexible tool model was defined, which can be used for various tool shapes without further experiments. This model can be applied for grinding processes with varying engagement situations.