Simulation of grinding process for cemented carbide based on an integrated process-machine model

Nowadays, the modeling and simulation of grinding have become powerful tools in predicting the process performance and work results. However, common simulations focus on material removal process of abrasive grains and neglect deformations of machine structure. The grinding quality can be influenced by various factors, of which the process-machine interaction results in often unpredictable effects, especially in the processing of hard-to-cut material. This paper proposes a simulation approach based on integrated process-machine model in plunge face grinding of cemented carbide. The approach synthesizes the interactive influence between machine dynamics and physical factors in grinding process. A virtual wheel model is built considering the stochastic nature of abrasive grains on the wheel surface, and the simulated forces and surface roughness are further predicted. The spindle-wheel structure is also modeled based on the finite element method. In order to implement the process-machine interaction, a coupled simulation by using self-developed interface is applied to accomplish data exchanges between different simulation environments. The simulation results are verified and found to be in good agreement with experimental results.