On modelling the interaction between two rotating bodies with statistically distributed features: an application to dressing of grinding wheels

Abstract

The mechanisms of interaction between bodies with statistically arranged features present characteristics common to different abrasive processes, such as dressing of abrasive tools. In contrast with the current empirical approach used to estimate the results of operations based on attritive interactions, the method we present in this paper allows us to predict the output forces and the topography of a simulated grinding wheel for a set of specific operational parameters (speed ratio and radial feed-rate), providing a thorough understanding of the complex mechanisms regulating these processes. In modelling the dressing mechanisms, the abrasive characteristics of both bodies (grain size, geometry, inter-space and protrusion) are first simulated; thus, their interaction is simulated in terms of grain collisions. Exploiting a specifically designed contact/impact evaluation algorithm, the model simulates the collisional effects of the dresser abrasives on the grinding wheel topography (grain fracture/break-out). The method has been tested for the case of a diamond rotary dresser, predicting output forces within less than 10% error and obtaining experimentally validated grinding wheel topographies. The study provides a fundamental understanding of the dressing operation, enabling the improvement of its performance in an industrial scenario, while being of general interest in modelling collision-based processes involving statistically distributed elements.