Applied mechanics in grinding. III: A new formula for contact length prediction and a comparison of available models

Abstract The contact length between a grinding wheel and a workpiece during operation is one of the principal factors that specify thermal and mechanical deformation of the workpiece. In this paper, we first propose a new formula for the contact length prediction, present a simple criterion to determine the applicable range of any approximate formulae, and then carefully compare our formula with available models, discuss their characteristics and limitations in application. Our comparison shows that the present formula is excellent in fitting experimental results from different types of operations that cover conventional and creep feed grinding. Moreover, it only needs a small number of input parameters, i.e. the normal grinding force, the depth of cut, the elasticity of grinding wheel and a condition coefficient, which are easily obtained in a grinding test.