Theoretical and experimental investigation on microcosmic surface generation in precision grinding with discrete method

Chen, Yizun (author), Sun, Yu (author)

Surface topography of the workpiece created in precision grinding is influenced by not only key process parameters, but also the distribution characteristics of active abrasive grits on the surface of the grinding wheel, including the number of active grits in the contact zone, the morphology of grits, and the cutting depth of a single grit in a normal direction. Under the conditions of small cutting depth (less than 5 μm) with small eccentrical rotation of the abrasive wheel (less than 3 μm), the influences of the original workpiece surface topography characteristics and the dynamic cutting depth of abrasive grits are often neglected in the study of microcosmic surface generation. In this paper, a discrete method (DM) is used to develop a theoretical kinematics model for the prediction of machined workpiece surface topography. Compared with the characteristics value of surface topography (scratch grooves) between experimental measurement and simulation output, the verification results from the improved prediction model of surface topography present well in comprehensively considering the influences of original surface characteristics, eccentrically rotational behavior of the abrasive wheel and the overlapped situation of scratch grooves on complex process conditions with a prediction error of about 10 %. In comparison with two commonly used empirical formulas in many other research studies, the prediction accuracy of the DM model for machined surface topography improves by 20 %. When calculating material removal volume, the prediction accuracy of incremental volume model of material removal increases approximately by 9 % to 19 % in comparison with the prediction results that take the whole cross-section area of an active grit as a key variable.

• Language: English
• Keywords: precision grinding, microcosmic surface topography, depth of cut, discrete method (DM), surface roughness
• Work type: Article
• Typology: 1.01 - Original Scientific Article
• Organization: FS - Faculty of Mechanical Engineering
• Publication status: Published
• Publication version: Version of Record
• Year: 2025
• Number of pages: 13 str.
• Numbering: Vol. 71, no. 11/12
• PID: 20.500.12556/RUL-178266
• UDC: 621
• ISSN on article: 2536-3948
• DOI: 10.5545/sv-jme.2025.1386
• COBISS.SI-ID: 265605123
• Publication date in RUL: 22.01.2026

Record is a part of a journal

• Title: Strojniški vestnik
• Shortened title: Stroj. vestn.
• Publisher: Fakulteta za strojništvo
• ISSN: 2536-3948
• COBISS.SI-ID: 294943232

Licences

• License: CC BY 4.0, Creative Commons Attribution 4.0 International
• Link: http://creativecommons.org/licenses/by/4.0/
• Description: This is the standard Creative Commons license that gives others maximum freedom to do what they want with the work as long as they credit the author.

Secondary language

• Language: Slovenian

Abstract

Topografija površine obdelovanca, ustvarjena pri preciznem brušenju, je odvisna ne le od ključnih procesnih parametrov, temveč tudi od porazdelitvenih značilnosti aktivnih abrazivnih zrn na površini brusnega kolesa, vključno s številom aktivnih zrn v kontaktni coni, njihovo morfologijo in globino reza posameznega zrna v normalni smeri. Pri majhnih globinah reza (manj kot 5 μm) in majhnih ekscentričnih rotacijah brusnega kolesa (manj kot 3 μm) se vplivi prvotne topografije površine obdelovanca ter dinamične globine reza abrazivnih zrn pogosto zanemarjajo pri proučevanju mikroskopske tvorbe površine. V tem članku je uporabljena diskretna metoda (DM) za razvoj teoretičnega kinematičnega modela za napoved topografije obdelane površine. Primerjava med izmerjenimi in simuliranimi vrednostmi značilnosti topografije (prask) je pokazala, da izboljšani napovedni model topografije površine dobro zajame vplive začetne površinske topografije, ekscentričnega vrtenja brusnega kolesa ter prekrivanja prask pri kompleksnih procesnih pogojih, z napako napovedi približno 10 %. V primerjavi z dvema pogosto uporabljenima empiričnima enačbama se natančnost napovedi modela DM za topografijo obdelane površine izboljša za 20 %. Pri izračunu volumna odstranjenega materiala se natančnost napovedi inkrementalnega volumskega modela odstranitve materiala poveča za približno 9 % do 19 % v primerjavi z rezultati napovedi, ki kot ključno spremenljivko upoštevajo celotno presečno površino aktivnega zrna.

• Keywords: precizno brušenje, mikroskopska topografija površine, globina reza, diskretna metoda (DM), hrapavost površine