Effect of Abrasive Grain Geometry on Cutting Forces in Grinding

Authors: Voronov S.A., Weidong Ma Published: 14.09.2017
Published in issue: #5(116)/2017  

DOI: 10.18698/0236-3941-2017-5-52-63

Category: Mechanical Engineering and Machine Science | Chapter: Technology and Equipment of Mechanical and Physical Processing  
Keywords: abrasive grain, finite element method, stress-strain state, temperature, grinding, cutting forces, micro-cutting

The article supplies the results of modelling the micro-cutting process for a single pyramid-shaped abrasive grain in preset modes featuring various cutting thicknesses and grain axis inclination angles (the rake angle of the cutting wedge). We investigate the processes of elastoplastic deformation, chip formation, cratering, built-up edge formation and burr formation when the tool cuts into materials; we also determine the ratio of cutting area to cutting force. To compute the stress-strain state parameters, we used the Johnson Cook material model that takes into account temperature along with strain rate and level. We solve the stress-strain state problem as stated together with the problem of temperature in the workpiece material. We determine cutting force coefficients and study the effect of rake angles in the grains on the cutting force coefficients


[1] Malkin S., Guo C. Grinding Technology: Тheory and applications of machining with abrasives. New York, Industrial Press, 2008. 372 р.

[2] Voronov S.A., Kiselev I.A., Ma V., Shirshov A.A. Numerical simulation of a grinding process model for the spatial work-pieces: development of modeling techniques. Nauka i obrazovanie: nauchnoe izdanie MGTU im. N.E. Baumana [Science and Education: Scientific Publication of BMSTU], 2015, no. 5, pp. 40–57 (in Russ.). DOI:10.7463/0515.0766577 Available at: http://technomag.edu.ru/jour/article/view/283

[3] Astakhov V.P., Shvets S. The assessment of plastic deformation in metal cutting. Journal of Materials Processing Technology, 2004, vol. 146, pp. 193–202. DOI:10.1016/j.jmatprotec.2003.10.015 Available at: http://www.sciencedirect.com/science/article/pii/S0924013603009981

[4] Zhang Y., Outeiro J.C., Mabrouki T. On the selection of Johnson – Cook constitutive model parameters for Ti–6Al–4V using three types of numerical models of orthogonal cutting. Procedia CIRP, 2015, vol. 31, pp. 112–117. DOI: 10.1016/j.procir.2015.03.052 Available at: http://www.sciencedirect.com/science/article/pii/S2212827115002504

[5] Wang S., Li C.H. Application and development of high-efficiency abrasive process // International Journal of Advanced Science and Technology, 2012, vol. 47, pp. 51–64. DOI: 10.4028/www.scientific.net/AMR.189-193.3113

[6] Li X. Modeling and simulation of grinding processes based on a virtual wheel model and microscopic interaction analysis: PhD Тhesis. Worcester, U.S., 2010. Pp. 4–12.

[7] Voronov S.A., Ma W. Simulation of chip-formation by a single grain of pyramid shape. Vibroengineering Procedia, 2016, vol. 8, pp. 39–44.

[8] Kilicaslan C. Modelling and simulation of metal cutting by finite element method: MS Thesis. İzmir, 2009. Pp. 22–23.

[9] Fang N. Tool-chip friction in machining with a large negative rake angle tool. Wear, 2005, vol. 258, no. 5-6, pp. 890–897. DOI: 0.1016/j.wear.2004.09.047 Available at: http://www.sciencedirect.com/science/article/pii/S0043164804003333

[10] Ohbuchi Y., Obikawa T. Finite element modeling of chip formation in the domain of negative rake angle cutting. J. Eng. Mater. Tech., 2003, vol. 125, no. 3, pp. 324–332. DOI: 10.1115/1.1590999 Available at: http://materialstechnology.asmedigitalcollection.asme.org/article.aspx?articleid=1427019

[11] Zherebtsov S., Salishchev G., Galeyev R. Mechanical properties of Ti–6Al–4V titanium alloy with submicrocrystalline structure produced by severe plastic deformation. Materials Transactions, 2005, vol. 46, no. 9, pp. 2020–2025. DOI: 10.2320/matertrans.46.2020 Available at: https://www.jstage.jst.go.jp/article/matertrans/46/9/46_9_2020/_article