Simulation of grinding surface topography considering wheel wear and wheel vibration

Grinding is widely used for machining high-precision parts, but grinding wheel wear and grinding wheel vibration significantly impact the surface quality of the parts in the process of machining. However, the effect of those two factors on the grinding surface has not been considered simultaneously in most grinding surface topography simulation studies. Hence, the paper conducts a simulation study of grinding surface topography with the consideration of the two factors. First, the actual topography of the grinding wheel surface is measured, and the surface topography of the grinding wheel is modeled accordingly. Second, the kinematic analysis of grinding is carried out and a mathematical model of grinding surface topography simulation, which involves grinding wheel wear and grinding wheel vibration, is constructed. Finally, grinding machining experiments are conducted to compare and analyze the surface topography and surface roughness of the actual and simulated grinding surfaces. The results show that the average relative errors of the four roughness parameter values between the simulated and actual grinding wheel surfaces are all below 2.5%. With the consideration of those two factors, the average relative errors of the surface roughness parameter values between the actual grinding surface and the corresponding simulated grinding surface are all less than 13.5%. This verifies the correctness and effectiveness of the method proposed in this paper. Improving the accuracy of the simulated grinding surface topography allows for better optimization of the selection of grinding machining parameters. It helps to precisely predict the surface topography and surface roughness of the grinding surface.