Influence of surface topography evolution of grinding wheel on the optimal material removal rate in grinding process of cemented carbide

Abstract Most of the reported studies on the optimization of grinding parameters do not consider the evolution of the surface topography of grinding wheels, and the established empirical models will no longer apply when the surface conditions of the grinding wheel changes. In this paper, an integrated model based on the surface topography of grinding wheel is established. The grinding process of cemented carbide is simulated using the established model, and the simulation results are analyzed to obtain the surface roughness model and the specific grinding energy model based on the undeformed chip thickness distribution. Subsequently, the grinding constraint models are defined according to the two grinding constraints—surface roughness and specific grinding energy. Through inversion analysis, the maximum material removal rate of the given grinding wheel surface conditions satisfying the defined grinding constraints are obtained, and the influence rules of the grinding wheel surface conditions on the maximum material removal rate are analyzed. Then the grinding wheel surface conditions are adjusted by changing the radial dressed height of the grinding wheel and the arrangement distance of the grains in wheel circumferential direction to improve the maximum material removal rate of the grinding wheel. Finally, the optimization results are verified through grinding tests of cemented carbide.