Modeling and simulation of grinding wheel by discrete element method and experimental validation

Abstract

A simulated grinding wheel (GW), a numerical representative that describes the geometric and physical properties of realistic GWs, is the prerequisite and foundation of grinding research. However, most proposed numerical GWs treated realistic GWs as continuums without internal structure (e.g., binder and pores) and analyzed realistic GWs' behaviors based on continuum-based material theories. To fill this gap, this study attempts to introduce a discontinuum-based method, discrete element method (DEM), into GW modeling and simulation. DEM GW simulation begins with two grindingcustomized modifications to classic DEM theory. Then, with the aid of experimental measurement and statistical analysis, a DEM GW is modeled. Experimental validations are conducted thereafter. Results show acceptable agreements between DEM and realistic GWs in terms of topography, microscopic structure, fracture behavior in compressive test, and performance in grinding process. The proposed DEM GW's ability in describing a discontinuous structure of realistic GWs covers the shortage of existing numerical GWs and might have other promising applications (e.g., GW formula optimization in production, GW preparation technology and parameter optimization, and GW wear and life prediction).Keywords Discrete element method . Grinding wheel . Modeling and simulationAbbreviation Scalar (in alphabetical order) a bHalf the length of octahedron minor axis (see Fig. 8a) a tHalf the length of spheriod minor axis (see Fig. 8aHalf the length of octahedron major axis (see Fig. 8a) b tHalf the length of spheriod major axis (see Fig. 8a)

Expectations and limitations of Cyber-Physical Systems (CPS) for Advanced Manufacturing: A View from the Grinding Industry

“…Given the nature of the grinding wheel structure, it should be regarded as a quasi-brittle material. In recent years, various research groups have focused their efforts on developing discrete element method (DEM) solutions to characterize the fracture behavior of these types of materials [32][33][34] Furthermore, in [35,36] the authors characterize the fracture behavior of the grinding wheel using a DEM model, they propose an experimental procedure for quantifying mechanical parameters (Brazilian test applied to grinding wheels) [35], and they describe tests for characterizing the grinding wheel material [36]. Unfortunately, this approach has not been validated for the classical problem of wheel wear.…”

On the inverse design of discontinuous abrasive surface to lower friction-induced temperature in grinding: An example of engineered abrasive tools

“…Considering the maximum-minimum difference of grain protrusions is approximately equal to the maximum-minimum difference of abrasive sizes [2] while the grain size was found to be normal-distributed [15,16], it therefore has…”

Discrete-element modelling of the grinding contact length combining the wheel-body structure and the surface-topography models

“…Li et al [5,6] propose the first DEM model of the grinding wheel. The model studies the stiffness and resistance of the grinding wheel, the force chain in the bonding material and predicts the surface roughness of the workpiece as a kinematic model.…”

“…Beams are massless since mass properties are assigned only to DE. Unlike Li et al [5,6], the volume fraction of binder does not match necessarily the beams volume, because their role is to provide stiffness to the model, not to represent realistically the geometry of bonding bridges.…”