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Methodology and Design for Abrasive Tools in Precision Grinding Processes.

Wojciech Kacalak¹, Katarzyna Tandecka¹, Łukasz Rypina¹

¹Department of Engineering and Informatics Systems, Faculty of Mechanical Engineering and Energy, Koszalin University of Technology, 75-620 Koszalin, Poland.

Materials (Basel, Switzerland)

|July 15, 2026

Summary

Optimizing abrasive tools for precision grinding involves analyzing active surface topography and tool wear. Abrasive aggregates significantly improve material removal efficiency and grinding stability compared to single grains.

Keywords:

FEM simulation Shos parameter abrasive tools active grain distribution aggregate structures grinding efficiency grinding wheel topography probabilistic modeling tool wear

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Area of Science:

Materials Science
Manufacturing Engineering
Tribology

Background:

Abrasive tool performance in precision grinding depends heavily on the active surface characteristics of the grinding wheel.
Key factors include the quantity, shape, and sharpness of the abrasive grains on the wheel's surface.

Purpose of the Study:

To develop a method for optimizing abrasive tools using active surface topography analysis, wear diagnostics, and micro-cutting simulations.
To investigate the role of the Shos parameter in characterizing machining potential and monitoring tool wear.

Main Methods:

Analysis of active surface topography and tool wear diagnostics.
Numerical simulation of micro-cutting processes involving single abrasive grains and abrasive aggregates.
Evaluation of the Shos parameter to assess machining potential and wear.

Main Results:

Abrasive aggregates demonstrated significantly different material removal behavior compared to single grains.
Under simulated conditions, aggregate geometry promoted chip formation and reduced lateral material displacement.
The material removal efficiency coefficient for aggregates (kr = 0.93) was substantially higher than for single grains (kr = 0.37).

Conclusions:

Abrasive aggregates positively influence material removal processes, enhancing the stability of precision grinding.
Future advancements in abrasive tools should incorporate controlled active surface structures and abrasive aggregates.
Diagnostic parameters linking tool topography, wear, and machining efficiency are crucial for tool improvement.