FORCE MODELING OF MICRO END GRINDING OF HARD AND BRITTLE MATERIALS

Abstract

Hard and brittle materials have broad application prospects in the defense, machinery and other fields, but hard machinability is crucial for its application. A promising processing method-micro end grinding (MEG), is put forward for machining microparts made of hard and brittle materials. Forces model of MEG is necessary to understand the effects of process, microgrinding wheel properties, material micro structure, etc, thereby allowing for process planning, optimization, and control. In this paper, a predictive model for MEG is developed by combined consideration of the undeformed chip thickness and the differences between up-grinding and down-grinding, and quantitatively predicts microgrinding forces. Experimental testing in a microgrinding configuration has been pursued to validate the predictive model by comparing measurements to analytical calculations. The analytical model is seen to capture the main trend of the experimental results, and many predictions are smaller than the experimental data of microgrinding. The average deviations in normal direction and tangential direction are analyzed lastly.