Modeling surface generation in ultra-precision grinding based on the surface topography of grinding wheel

Abstract

This paper presents a new modeling method for analyzing the surface generation based on modeling surface topography of the grinding wheel. Since the high spindle speed of grinding wheel as compared with that of the workpiece, the same area of workpiece surface is ground many times by different protrusion points on the grinding wheel. It is difficult to model all the grinding trajectories of each abrasive grain not only because of the difficulty to obtain all accurate kinematic equations but also due to a huge amount of calculations. The model presented in this paper firstly filters the protrusion points on the grinding wheel which primarily determine the surface generation of the workpiece. Hence, the kinematic trajectory model is built by considering the spindle speed of both the grinding wheel and the workpiece. It is found that the simulation efficiency improves greatly due to the method of filtering grinding points. As a whole, this paper presents an effective way to model the surface generation in ultra-precision grinding.