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<p>Grinding force and workpiece topography are key factors determining the quality of material processing and production efficiency. This paper&#xa0;considers&#xa0;the impact of wheel topography on grinding force, including the roller dressing process in its research scope. First, the initial surface topography of the randomly generated grinding wheel is numerically simulated. Subsequently, the corresponding dressing trajectory and the dressed wheel topography are generated based on the given dressing parameters. In this process, the mapping relationship between the roller dressing parameters and the surface topography of the grinding wheel is revealed.&#xa0;This dressed topography is applied to an ultrasonic grinding model to calculate the instantaneously evolving undeformed chip thickness (UCT) and its distribution characteristics, thereby analyzing the mechanical behavior at various grinding stages and constructing an ultrasonic vibration grinding force model. Finally, the wheel surface and force prediction models are verified via wheel dressing and ultrasonic vibration-assisted&#xa0;grinding (UVAG) experiments. The results demonstrate that the average error between the simulated and experimental values of the grinding wheel dressing model is 11.6%, while the average error between the theoretical predictions and measured values of the grinding force is 17.3%, confirming the model’s effectiveness.</p>

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Modelling of ultrasonic grinding force considering the wheel topography generated by rotary dressing operation

  • 期刊论文

  • 发表日期：

    2025年8月22日

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  • Yanqin Li,
  • Yuanshuai Yang,
  • Jiajun Xiong,
  • Peicheng Peng,
  • Daohui Xiang

摘要

Grinding force and workpiece topography are key factors determining the quality of material processing and production efficiency. This paper considers the impact of wheel topography on grinding force, including the roller dressing process in its research scope. First, the initial surface topography of the randomly generated grinding wheel is numerically simulated. Subsequently, the corresponding dressing trajectory and the dressed wheel topography are generated based on the given dressing parameters. In this process, the mapping relationship between the roller dressing parameters and the surface topography of the grinding wheel is revealed. This dressed topography is applied to an ultrasonic grinding model to calculate the instantaneously evolving undeformed chip thickness (UCT) and its distribution characteristics, thereby analyzing the mechanical behavior at various grinding stages and constructing an ultrasonic vibration grinding force model. Finally, the wheel surface and force prediction models are verified via wheel dressing and ultrasonic vibration-assisted grinding (UVAG) experiments. The results demonstrate that the average error between the simulated and experimental values of the grinding wheel dressing model is 11.6%, while the average error between the theoretical predictions and measured values of the grinding force is 17.3%, confirming the model’s effectiveness.