Material removal rate model for high-shear and low-pressure grinding with body-armor-like wheel

doi:10.1007/s40436-025-00550-3

Advances in Manufacturing ›› 2026, Vol. 14 ›› Issue (1): 189-210.doi: 10.1007/s40436-025-00550-3

• • 上一篇

Material removal rate model for high-shear and low-pressure grinding with body-armor-like wheel

Ye-Bing Tian, Bing Liu, Xiao-Mei Song, Shuang Liu, Guo-Yu Zhang

School of Mechanical Engineering, Shandong University of Technology, Zibo, 255049, Shandong, People's Republic of China

收稿日期:2024-03-25 修回日期:2024-07-23 发布日期:2026-03-23
通讯作者: Ye-Bing Tian Email:E-mail:tianyb@sdut.edu.cn E-mail:tianyb@sdut.edu.cn
作者简介:Ye-Bing Tian born in 1979, is a full professor in School of Mechanical Engineering, Shandong University of Technology, China. He received his PhD from Dalian University of Technology, in 2007. His research interest is precision and ultra-precision machining.
Bing Liu born in 1989, is currently studying in School of Mechanical Engineering, Shandong University of Technology, China. His research interest is ultra-precision grinding.
Xiao-Mei Song born in 1980, received her M.E. degree in Intelligent Systems from Ibaraki University, Japan in 2011. She joined Shandong University of Technology in 2017. Her research interest is precision and ultra-precision machining.
Shuang Liu born in 1998, is currently studying in School of Mechanical Engineering, Shandong University of Technology, China. Her research interest is ultra-precision grinding.
Guo-Yu Zhang born in 1998, is currently studying in School of Mechanical Engineering, Shandong University of Technology, China. His research interest is ultra-precision grinding.
基金资助:
This work was financially supported by the National Natural Science Foundation of China (Grant No. 51875329), the Shandong Provincial Natural Science Foundation, China (Grant No. ZR2023ME112), the Taishan Scholar Special Foundation of Shandong Province (Grant Nos. tstp20240826, tsqn201812064), and the Innovation Capacity Improvement Programme for High-tech SMEs of Shandong Province (Grant Nos. 2022TSGC1333, 2022TSGC1261).

Material removal rate model for high-shear and low-pressure grinding with body-armor-like wheel

Ye-Bing Tian, Bing Liu, Xiao-Mei Song, Shuang Liu, Guo-Yu Zhang

School of Mechanical Engineering, Shandong University of Technology, Zibo, 255049, Shandong, People's Republic of China

Received:2024-03-25 Revised:2024-07-23 Published:2026-03-23
Contact: Ye-Bing Tian Email:E-mail:tianyb@sdut.edu.cn E-mail:tianyb@sdut.edu.cn
Supported by:
This work was financially supported by the National Natural Science Foundation of China (Grant No. 51875329), the Shandong Provincial Natural Science Foundation, China (Grant No. ZR2023ME112), the Taishan Scholar Special Foundation of Shandong Province (Grant Nos. tstp20240826, tsqn201812064), and the Innovation Capacity Improvement Programme for High-tech SMEs of Shandong Province (Grant Nos. 2022TSGC1333, 2022TSGC1261).

摘要/Abstract

摘要： High-shear and low-pressure grinding with a body-armor-like grinding wheel is a novel grinding method with great potential for ultraprecision machining of difficult-to-cut materials. However, the material removal rate model for the new grinding process is still lacking. In this study, elastohydrodynamic pressure distribution at the working interface between a body-armor-like grinding wheel and the workpiece was revealed. The microcontact state of the single abrasive grain in the interface was uncovered. The formulas of the forces acting on the rubbing, plowing, and cutting abrasive grain were analyzed. Based on the force model of the single abrasive grain and the Gaussian distribution of the grain protrusion heights, the actual grinding depth of the cut model and specific removal rate model were proposed for the novel high-shear and low-pressure grinding process. The influence of the grinding wheel and processing parameters on the material removal rate was investigated. It was found that the actual cut grinding depth decreased with the increase of the workpiece feed rate while the material removal rate remained almost constant. By comparing with experimental and theoretical results, it was shown that the model could accurately predict the actual grinding depth of cut and specific removal rate under different processing parameters, with a minimum prediction error of 1.5%. The maximum actual grinding depth of cut (i.e., 0.60 μm), was obtained for Inconel 718 workpiece. The findings of this study provide theoretical guidance for the practical application of high-shear and low-pressure grinding.

The full text can be downloaded at https://doi.org/10.1007/s40436-025-00550-3

关键词: High-shear and low-pressure grinding, Material removal model, Elastohydrodynamic pressure, Body-armor-like grinding wheel

Abstract: High-shear and low-pressure grinding with a body-armor-like grinding wheel is a novel grinding method with great potential for ultraprecision machining of difficult-to-cut materials. However, the material removal rate model for the new grinding process is still lacking. In this study, elastohydrodynamic pressure distribution at the working interface between a body-armor-like grinding wheel and the workpiece was revealed. The microcontact state of the single abrasive grain in the interface was uncovered. The formulas of the forces acting on the rubbing, plowing, and cutting abrasive grain were analyzed. Based on the force model of the single abrasive grain and the Gaussian distribution of the grain protrusion heights, the actual grinding depth of the cut model and specific removal rate model were proposed for the novel high-shear and low-pressure grinding process. The influence of the grinding wheel and processing parameters on the material removal rate was investigated. It was found that the actual cut grinding depth decreased with the increase of the workpiece feed rate while the material removal rate remained almost constant. By comparing with experimental and theoretical results, it was shown that the model could accurately predict the actual grinding depth of cut and specific removal rate under different processing parameters, with a minimum prediction error of 1.5%. The maximum actual grinding depth of cut (i.e., 0.60 μm), was obtained for Inconel 718 workpiece. The findings of this study provide theoretical guidance for the practical application of high-shear and low-pressure grinding.

The full text can be downloaded at https://doi.org/10.1007/s40436-025-00550-3

Key words: High-shear and low-pressure grinding, Material removal model, Elastohydrodynamic pressure, Body-armor-like grinding wheel

Ye-Bing Tian, Bing Liu, Xiao-Mei Song, Shuang Liu, Guo-Yu Zhang. Material removal rate model for high-shear and low-pressure grinding with body-armor-like wheel[J]. Advances in Manufacturing, 2026, 14(1): 189-210.

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Material removal rate model for high-shear and low-pressure grinding with body-armor-like wheel

Material removal rate model for high-shear and low-pressure grinding with body-armor-like wheel

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