Study on the grinding force of single grain in rail grinding based on open-type belt grinding

In the realm of machining, there exists a heightened demand for improved surface integrity of workpieces. Abrasive belt grinding presents several advantages, including a high grinding ratio, superior surface finish quality, and lower grinding temperature. Additionally, the precision placement of abrasive grains in the form of triangular pyramids further enhances the efficacy of this method. It has played an important role in the field of precision machining. Accurately predicting its grinding force is vital for improving its processing quality. In this study, an open-type belt grinding method was developed, the grinding force of triangular pyramid-shaped abrasive grains in rail grinding was analyzed and calculated using oblique cutting theory, the accuracy of the proposed model was verified experimentally, and the effects of abrasive rotation angle, wear height, cutting depth, grinding speed, and rake angle on the grinding force were analyzed, and the relevant laws were obtained. According to the findings, the grinding force displays an initial rise followed by a decline as the triangular pyramid abrasive particles' rotational angle increases. The grinding force demonstrates a linear growth in tandem with an increase in grinding depth. Furthermore, the grinding force rises proportionally with an increase in abrasive wear height. The proposed model can be used for the prediction and calculation of grinding forces of other shape abrasive grains as well.