Research on the embossment phenomenon of disc grinding by workpiece's removal rate

Abstract The disc grinding has become a widely used technology in the precision-manufacturing process for plate stainless steel. However, embossment phenomenon occurs on the ground workpiece's surface. Moreover, the workpiece's removal rate can be applied to measure the embossment. In most studies, the researches on the disc grinding technology mainly focus on the trajectory distributions, which might be not appropriate enough to capture the workpiece's removal rate. To this end, this paper has presented a multiple grits-discretized (MGD) model on the workpiece's removal rate to identify the formation mechanism of the embossment phenomenon. Meanwhile, the current model is established based on the grits’ distributions, the grits’ size and the kinematic multiple grits’ trajectory. The theoretical prediction for the distribution of workpiece's removal rate shows a reasonable agreement with the experimental validation. It shows that the removal rate is non-uniformly distributed on the workpiece's surface, which results in the workpiece's embossment. Furthermore, the workpiece's removal rate is greatly affected by the speed ratio. Therefore, the proposed model is not only anticipated to be meaningful for improving the uniformity of the machined workpiece by adjusting the speed ratio, but also expected to be useful for enhancing the understanding on the disc grinding enterprises.