Chip formation mechanisms in grinding at low speeds

Grinding processes characterised by cutting speeds as low as 0.3...5 m/s are becoming more and more important amongst abrasive technologies for finishing of hardened gears. A number of research work carried out in this area in the past few years has significantly improved the understanding of common technological interdependencies. However, there is still a lack of knowledge about the main chip formation mechanisms at such low speeds. In order to investigate these mechanisms, single grit scratching tests and grinding experiments have been performed. The cutting speed and the chip thickness were identified as main quantities determining the chip formation process. These results can be used for design of grinding processes and development of suitable abrasive tools.