Methodology and Design for Abrasive Tools in Precision Grinding Processes

The workability of abrasive tools for precision grinding is significantly affected by the quality of active surface of grinding wheel in terms of the number, form, and sharpness of active abrasive grains. The aim of this study is to introduce a method for optimizing the abrasive tools based on active surface topography analysis, tool wear diagnostics, and numerical simulation of micro-cutting by one active grain and abrasive aggregate. Particular attention is given to the Shos parameter, which characterizes the machining potential of a grinding wheel by combining information on the height and sharpness of active abrasive grain vertices. Changes in this parameter allow observation of the blunting and wear of the active surface. Numerical simulation shows that material removal by one active grain and by an abrasive aggregate differs significantly. According to the obtained data, under the assumed micro-cutting conditions, the aggregate geometry reduced lateral material displacement and promoted chip formation. The coefficient of material removal efficiency for aggregate was equal to kr = 0.93 compared to kr = 0.37 for one grain. Therefore, abrasive aggregates have an effect on the material removal process and may support the improvement of the stability of precision grinding. Thus, it can be concluded that further improvements in abrasive tools require considering controlled active surface structures and abrasive aggregates, as well as diagnostic parameters that relate tool topography to wear and machining efficiency.