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An Equivalent Chip Coefficient Towards an Adaptive Controlled Grinding Process

In this investigation the grinding process of the three grinding modes, external cylindrical, surface and internal cylindrical grinding, has been simulated over a wide range of input parameters. The analyses have led to the definition of a grinding coefficient, which is a collective combination of input parameters: work speed wheel speed vs and depth of cut. Grinding results of cutting forces, surface roughness and grinding ratio were represented in a grinding chart as logarithmic-linear functions of the grinding coefficient. Independent from the grinding mode a direct relationship was found between the output results and the grinding coefficient. Only one line is needed to describe the influence of all the input parameters on the output results (grinding forces, surface roughness and grinding ratio) independently from the grinding mode, thus eliminating the controversial effect of each of the individual input parameters (vs, vw and a) as well as the grinding model (surface, external and internal cylindrical grinding). The results are used to develop a grinding model for the cutting forces, grinding wheel wear and surface roughness. A design of an adaptive controlled grinding process is discussed.