Surface generation model in grinding with effect of grain shape and cutting speed

To simulate cutting with abrasive grain in grinding, a random grain shape is modeled. The statistical distribution of the effective rake angles of abrasive grain is obtained by applying Usui's four models of kinematically admissible velocity fields. The material is removed in the case of complete chip or incomplete chip formation, but is not removed when wall of partial chip or plastic upheaval is generated. Next, residual stock removal by bulging, which occurs due to effect of cutting speed, is presumed. A critical undeformed chip thickness, under which chip forms with great difficulty, is introduced. For further strict modeling, three components of cutting force are evaluated. As a result, a new model of surface generation process in grinding considering upheaval or residual stock removal, which is caused by the effect of grain shape and cutting speed, and of elastic deformation, is proposed.