Modeling of micro-grinding forces considering dressing parameters and tool deflection

The prediction of cutting forces is critical for the control and optimization machining processes. This paper concerned with developing model in micro-grinding. approach based on probabilistic distribution undeformed chip thickness. a function process kinematics, properties workpiece, micro-topography grinding tool. A Rayleigh probability density used to determine maximum thickness as an independent parameter. further includes effect dressing parameters. integration enables static grain tool at various radial depths. deflection also considered order account actual depth cut modeling process. dynamic cutting-edge density, local deflection, elastic deformation, kinematics can hence be calculated. Once calculated, single-grain individual abrasive grains are predicted specific tangential normal simulated. simulation results experimentally validated via cutting-force measurements micro-grinding Ti6Al4V. show that predict mean accuracy 10% 30%, respectively. observed imply flow stress material did not change changing speed strain rate. Moreover, it was feed rate had same neutral resultant forces.