Analytical modeling of cutting forces in grinding of AISI 1060 heat treated steel considering undeformed chip thickness distribution

The grinding process is one of the most important and widely used machining processes to achieve the desired surface quality and dimensional accuracy. Since the undeformed chip thickness is not a constant value in the grinding process and is changing independently and momentarily for each abrasive, the determination of the undeformed chip thickness accurately is essential to determine the grinding forces and surface topography of the grinding wheel. Previous studies on grinding forces were mainly regardless of the micro-mechanisms between the abrasive and the workpiece. On the other hand, only the average values ​​of forces could be calculated by determining the average value for undeformed chip thickness. In this study, a new analytical model with the approach of kinematic-geometric analysis of abrasive grain trajectory is presented to determine the undeformed chip thickness and subsequent grinding forces. This model predicts the components of normal and tangential grinding forces (including sliding, plowing, and cutting forces) accurately and in detail based on the instantaneous undeformed chip thickness obtained from the kinematic analysis of abrasive movement and micro-mechanisms between abrasive and the workpiece. In the end, experimental tests were performed to validate the theoretical model.