A Grinding Force Prediction Model with Random Distribution of Abrasive Grains: Considering Material Removal and Undeformed Chips

Grinding force is an important index for understanding grinding mechanism. In this paper, based on the single grain-grinding experiment, the grinding force under different grinding parameters was studied. Based on the undeformed chip, the grinding force model of multi-grain abrasive was established. Combined with the randomness of grains distribution, the grinding force model was further improved. And the grinding specific energy under different undeformed chip thickness was obtained by single CBN abrasive grain scratch tests. In addition, grinding experiments were carried out under different grinding parameters, and corresponding grinding force was measured. The results show that the grinding specific energy changes with the change of the undeformed chip thickness. For grinding 45 steel with ceramic bond CBN wheel, when the deformation cutting thickness reaches 50 μm, the grinding specific energy tends to 3460 J/mm3. Under the same grinding parameters, the calculated values of grinding force model are in good agreement with the experimental values. Confirmed by further research, the model has better applicability to small cutting depth, slow feed, and low speed cutting models. This study has certain guiding significance for further research on grinding mechanism and characterizing the grinding force.