On the evolution of metal-bonded microgrinding tool topography due to wear

Abstract

Abstract The key challenge in the analysis of the grinding process involves the characterization of tool topography due to a large degree of randomness in the grit shapes, sizes, orientation and distribution. The effect of random tool topography on the output characteristics is even more pronounced in microgrinding. During the process, the wear of bond and grits cause the exposure of the underlying grits of the multi-layered metal bonded microgrinding tools. Due to the random tool topography and its variation during grinding due to continuous wear and self-dressing makes the process analysis highly complex. This study proposes a model that characterizes the multi-layered metal bonded microgrinding tool topography and its evolution during the process caused due to wear. The effects of both grit and bond wear on topography evolution is investigated. The emergence of new grits due to bond wear during the tool-workpiece interaction has also been captured in the model. Individual grit life cycle has been analyzed and the number of protruding, active, dislodged and worn out grits at a given machining time is estimated. Statistical analysis of the protrusion height distribution is carried out which gives an insight into the effect of wear on the height distribution variation.