Experimental study on force model in grinding of maraging steel 3J33

Grinding is always a complicated machining process for joint interaction of numerous random abrasive grits in different chip formation processes. Therefore, analysis of grinding force requires a more comprehensive insight on the grinding mechanisms. This paper is devoted to propose an analytical force model in grinding of maraging steel 3J33 based on the fact that grinding process is divided into three stages, namely rubbing, ploughing and cutting, in terms of grits working status. These three stages are determined by the chip thickness model that is assumed to conform to Rayleigh distribution, in which the rubbing stage is derived from Hertzian contact theory. The experimental coefficients in the force model are calibrated by performing a set of training tests. The predicted normal and tangential grinding forces of the developed model are compared with those obtained from validation tests, which show favorable agreement quantitatively. The contributions of the grinding force components in different grit–workpiece interaction stages are obtained from the model and theirs relationships with process parameters are discussed.