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<p>At high rotational speeds, ultra-thin grinding wheels undergo elastoplastic deformation due to the combined effects of centrifugal and grinding forces. This deformation causes the actual cutting depth to deviate from the theoretical depth, thereby compromising machining accuracy. To address this issue, this study establishes a mathematical model incorporating the concept of dynamic diameter (<i>D</i><sub><i>d</i></sub>). By comparing finite element simulations with experimental measurements, the study identifies the key factors influencing <i>D</i><sub><i>d</i></sub>. It is found that the dynamic diameter evolves through two distinct stages: elastic and plastic deformation. Based on these results, this paper optimises the theoretical formula for calculating the dynamic diameter and innovatively introduces a plasticity compensation coefficient derived from a bilinear isotropic hardening model, thereby enabling, for the first time, a quantitative analysis of irreversible radial expansion under high-speed conditions. Furthermore, the work provides a mechanistic link between the macroscopic <i>D</i><sub><i>d</i></sub> and the microstructural plastic flow of the metallic binder. These findings not only provide guidance for investigating the elastoplastic behavior of wheels in high-speed precision cutting but also offer critical insights for designing ultra-thin grinding wheels with minimal deformation and enhanced wear resistance.</p>

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Analysis of elastoplastic deformation of ultra-thin grinding wheels at high speeds

  • 期刊论文

  • 发表日期：

    2026年5月23日

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  • Zhiqiang Xu,
  • Jiawei Dong,
  • Xiaojie Liu,
  • Shengqiang Jiang,
  • Hongliang Yang,
  • Sheng Gong,
  • Zhonglin Tan

摘要

At high rotational speeds, ultra-thin grinding wheels undergo elastoplastic deformation due to the combined effects of centrifugal and grinding forces. This deformation causes the actual cutting depth to deviate from the theoretical depth, thereby compromising machining accuracy. To address this issue, this study establishes a mathematical model incorporating the concept of dynamic diameter (Dd). By comparing finite element simulations with experimental measurements, the study identifies the key factors influencing Dd. It is found that the dynamic diameter evolves through two distinct stages: elastic and plastic deformation. Based on these results, this paper optimises the theoretical formula for calculating the dynamic diameter and innovatively introduces a plasticity compensation coefficient derived from a bilinear isotropic hardening model, thereby enabling, for the first time, a quantitative analysis of irreversible radial expansion under high-speed conditions. Furthermore, the work provides a mechanistic link between the macroscopic Dd and the microstructural plastic flow of the metallic binder. These findings not only provide guidance for investigating the elastoplastic behavior of wheels in high-speed precision cutting but also offer critical insights for designing ultra-thin grinding wheels with minimal deformation and enhanced wear resistance.