Improved force prediction model for grinding Zerodur based on the comprehensive material removal mechanism

Area of Science:

• Materials Science
• Manufacturing Engineering
• Mechanical Engineering

Background:

• Limited research exists on force models for grinding brittle materials.
• Dynamic material removal mechanisms in brittle materials require further elucidation.

Purpose of the Study:

• To propose an improved grinding force model for Zerodur, incorporating ductile removal, brittle removal, and frictional forces.
• To accurately predict grinding forces by analyzing grain-workpiece interactions and material characteristics.

Main Methods:

• Developed a model considering critical uncut chip thickness (a_gc) and maximum uncut chip thickness (a_gmax) to define material removal modes.
• Utilized indentation fracture tests to obtain Zerodur's mechanical properties for the brittle removal force model.
• Derived model coefficients through experimental data and validated the model with three grinding experiments.

Main Results:

• The improved model accurately predicts grinding forces, with relative mean errors of 6.04% for normal force and 7.22% for tangential force.
• The model effectively predicts correlations between grinding force and grinding parameters.
• Validation experiments confirmed the model's capability to represent realistic grinding forces.

Conclusions:

• The proposed grinding force model offers accurate predictions for brittle materials like Zerodur.
• The model enhances understanding of material removal mechanisms during the grinding of brittle substances.
• This work provides a valuable tool for optimizing grinding processes for brittle materials.