MODELING AND SIMULATION OF CUTTING FORCES IN SURFACE GRINDING PROCESS AT MICRO LEVEL USING MATLAB
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Date
2023-02
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G. B. Pant University of Agriculture & Technology, Pantnagar-263145
Abstract
Grinding is a major manufacturing process that accounts for approximately 20–
25% of total machining expenditures in industrialized countries. Everything used
todayhas been machined by grinding at some point in its manufacturing process or has
been produced by machines that owe their functionality to grinding operations.
Grinding forces play a key role in the grinding process by influencing the specific
power consumption, heat generation at the interface of abrasive cutting grains and the
workpiece, quality of the ground workpiece surface and various other performance
parameters. So, a mathematical model to estimate the grinding forces would help to
achieve the target. Previously developed models were usually based on the assumption
which might contradict with the reality as they didn’t consider the grain-workpiece
interaction at the micro level (i.e., rubbing, ploughing and cutting). Also, most previous
studies could only be used to predict average values on wheel basis of grinding forces
because the most models were built based on average grain cutting depth or average
chip thickness, and none of the grinding force details at the micro level.
A new model to predict the grinding forces at micro levelof grain-workpiece
interaction have been developed in the present study and validated with help of
MATLAB and data available in the previous studies. The effects of grinding
parameters such as depth of cut, workpiece speed, wheel speed and size of abrasive
grains was studied. The predicted grinding forces were almost identical to the grinding
forces experimentally estimated by the previous researchers, with an average
percentage error of 6.09%. It was found that the Size of the abrasive grains (abrasive
grit number) have the largest impact on rubbing, ploughing and cutting contributions.
Depths of cut have the second largest effects and the dominant force component could
probably be changed from rubbing to cutting by using different cut depths. The effects
of wheel speeds can also be seen: fast wheel speeds lead to less rubbing forces and
more cutting forces, while the effects of workpiece feed rates seem to be limited.
Therefore, high wheel speeds and large workpiece feed rates are recommended to
achieve high material removal rates.
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Theses of Ph.D