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<p>During the outer contour grinding of silicon nitride (Si<sub>3</sub>N<sub>4</sub>), the material’s hard and brittle properties have been shown to significantly accelerate the wear of diamond grinding wheels. This necessitates frequent wheel dressing during machining, thus rendering grinding wheel wear a pivotal factor in determining the contour accuracy and surface finish of the roller’s external cylindrical surface. In conventional practice, dressing strategies are predominantly empirical, and the underlying mechanism by which wheel wear induces profile errors remains insufficiently elucidated. In order to address these challenges, a profile error prediction model was developed based on grinding ratio theory, with the radial wear of the grinding wheel being a specific consideration. The investigation systematically explored the influences of roller geometry, wheel specifications, and grinding parameters on the evolution of profile errors, with the cumulative number of processed rollers designated as the independent variable. Taking a <i>ϕ</i> 5&#xa0;mm × 5.4&#xa0;mm silicon nitride spherical roller with a profile error threshold of 5&#xa0;μm as an example, it is necessary to ensure that the grinding wheel is dressed after no more than 20 rollers have been machined consecutively. The maximum deviations between the model predictions for grinding wheel wear (∆<i>R</i>) and profile error (∆<i>ε</i>) and the experimental values were 17.605% and 13.612%, respectively. The research findings provide theoretical guidance for establishing grinding wheel dressing cycles during the roller grinding process and for controlling the geometric accuracy of ceramic spherical rollers.</p>

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Prediction model of profile error induced by wheel wear in outer contour grinding of Si3N4 spherical rollers

  • 期刊论文

  • 发表日期：

    2026年7月14日

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  • Songhua Li,
  • Chi Jin,
  • Zichen Zhao,
  • Chuang Zuo,
  • Gefei Lin,
  • Xiangyun Pang

摘要

During the outer contour grinding of silicon nitride (Si3N4), the material’s hard and brittle properties have been shown to significantly accelerate the wear of diamond grinding wheels. This necessitates frequent wheel dressing during machining, thus rendering grinding wheel wear a pivotal factor in determining the contour accuracy and surface finish of the roller’s external cylindrical surface. In conventional practice, dressing strategies are predominantly empirical, and the underlying mechanism by which wheel wear induces profile errors remains insufficiently elucidated. In order to address these challenges, a profile error prediction model was developed based on grinding ratio theory, with the radial wear of the grinding wheel being a specific consideration. The investigation systematically explored the influences of roller geometry, wheel specifications, and grinding parameters on the evolution of profile errors, with the cumulative number of processed rollers designated as the independent variable. Taking a ϕ 5 mm × 5.4 mm silicon nitride spherical roller with a profile error threshold of 5 μm as an example, it is necessary to ensure that the grinding wheel is dressed after no more than 20 rollers have been machined consecutively. The maximum deviations between the model predictions for grinding wheel wear (∆R) and profile error (∆ε) and the experimental values were 17.605% and 13.612%, respectively. The research findings provide theoretical guidance for establishing grinding wheel dressing cycles during the roller grinding process and for controlling the geometric accuracy of ceramic spherical rollers.