On the evaluation of grinding wheel surface condition under different process parameters via in-machine monitoring

Abstract

Abstract The role of the grinding wheel is significant in all grinding operations. Two main indicators related to the process behaviour are the ground workpiece surface roughness and the consumed amount of energy. Both of these factors are affected by grinding wheel topography condition. Thus, an in-deep analysis of the wheel surface condition will extend the understanding of both process behaviour and wheel performance. This condition can be described by the micro-wear mechanisms such as flattening of abrasive grits (wear flat) and adhesion of chips between grits and pores (wear by deposition or loading) in conjunction with the arrangement of abrasive grains. In this sense, in this work a tool for in-machine analysis of wheel surface features such as attritious wear, loading and the number of grains involved in the cutting action is developed. The device is then used in experimental tests in order to validate its ability to analyse the wheel-process behaviour. Researchers have deeply studied the influence of the wheel wear condition on the grinding process, but there is still a lack of knowledge on the effect that both grinding and dressing processes have on the wheel wear condition evolution. The developed tool is also employed for that purpose. Results obtained with the device are consistent with previous works and literature. Therefore, it can be used for a comprehensive understanding of process behaviour during grinding with different wheel-workpiece material combinations and different process conditions, as well as for the analysis and optimization of new abrasives and bonds performances.