Design of Experiments Based Force Modeling of the Face Grinding Process

A grinding force model is developed to predict the forces during the face grinding of cast iron and aluminum alloy 319. Design of experiments methods are used to create a response surface of four process parameters: feed rate, inclination angle of the grinding wheel profile, offset angle between the grinding wheel and the workpiece, and the peripheral speed of the wheel. For each material, three polynomial equations are determined by regression analysis to represent the forces in three directions. The model shows better accuracy for cast iron than aluminum alloy. The feed rate and inclination angle have the most significant effect on the grinding forces. The model is simple and can be implemented in industry quickly after a few test runs. However, it has limited accuracy, generally within 10-20% on the prediction of grinding forces.