Unified approach to developing analytical models of different grinding processes based on basic cutting process model

Abstract

Abstract The appearance of modern CNC grinding machines allowed concentrating multipass and multistage processing of different workpiece surfaces by means of using different grinding types and different tool types. Meanwhile, the processing of different surfaces is carried out with different allowances and accuracy requirements and performed according to the specified stepwise cycles of the feeds control. As a result, there is a difficult task of quick and reliable calculation of the optimal feed cycles and other cutting modes for different types of processing of different surfaces with various grinding conditions. The solution to this problem is developing of mathematical models that link processing accuracy with cutting modes and other technological conditions of the processing. The development of such models should begin with the creation of a complex of the cutting forces` models for each grinding type. This article describes a method for deriving generalized analytical model of the cutting force for the different grinding types which is based on the functional interrelation between the intensity of the metal removal performed by the wheel and elementary volumes of metal deformable in the shear zone. The complex of the cutting forces models for different grinding types, obtained by means of using this technique, establishes functional interrelation of the cutting force with cutting modes, strength properties of the treated material, kinematics of the grinding process, geometry of the cutting zone, characteristics and geometric parameters of the grinding wheel, etc. It should also be noted that the developed models cover the majority of production conditions and they are wide-range in terms of the main technological parameters (dimensions of the treated surfaces, allowances, tolerance grades, etc.).