Method of Determination of Microcutting Process Parameters in Grinding

Abstract

The change in the geometric shape of the abrasive tool as a result of the wear of the working surface (WS) of the abrasive tool and the blunting of the vertices of the cutting grains leads to significant changes in the statistical indices of their distribution in the volume of the working layer of the grinding wheel. Investigation of the process of interaction of the abrasive tool with workpiece and determination of the process parameters taking into account the characteristics and current conditions of the working surface of the tool allowed the development of calculation methods for determining the optimum strength of fastening abrasive grains on the working surface of the grinding wheel and power parameters of the grinding process. The paper describes the research technique and presents the results containing data on the interaction parameters of the vertices of active abrasive grains of the grinding wheel with the workpiece in the zone of their contact. The studies were carried out using the developed computer geometric and statistical-probabilistic models of the working surface of the instrument and the processing process created using engineering 3D CAD «T-Flex CAD». The use of computer models has made it possible to determine the shape and dimensions of the cross-section of cut-off chips, taking into account the parameters of the grinding mode and the characteristics of the tool. Application of the proposed methodology, developed using basic mathematical models, allowed to determine discrete and integral indicators of microcutting of the abrasive process. In the course of the studies, a complex parameter γ, characterizing the specific productivity of a unit area of the working surface of the tool, was used in the calculations. The regression analysis carried out in STATISTICA10 software package with the purpose of estimating the influence of the change of the investigated factors on the parameters of the interaction of the tool with the work made it possible to obtain the dependences of the density of vertices of active grains in the contact zone r and the average cutting forces Ppt on the complex coefficient g.