Model of tool loads in dry diamond wire grinding of steel

Dry diamond wire grinding of steel is associated with high tool wear restricting productivity as well as tool life. Therefore, the process has to be designed properly to ensure an economic cut. This paper introduces a process model for the dry diamond wire grinding of steel based on analytical and experimental results. The model describes fundamental influences of input parameters on mechanical and thermal tool loads by means of process kinematics and undeformed chip parameters. It is shown that tool temperatures are directly related to tangential grinding forces. The model is verified by experimental results showing high correlation of calculated and measured values.