Study on the surface topography considering grinding chatter based on dynamics and reliability

Surface grinding is always accompanied with chatter due to self-excited vibration. It often leads to an unexpected impact on the quality of the workpiece’s topography. However, the chatter is regarded as a harmonic vibration in most topography researches. This may lose preciseness when the relative vibration and the abrasive trajectory are taken into consideration. In order to study the relationship between the system’s dynamic characteristic and the workpiece’s topography, a two-DOF (degree of freedom) dynamic model with time-delay characteristic is established accordingly. Then, reliability analysis is introduced into chatter vibration by analyzing the fluctuations of dynamic parameters with two analysis methods, namely Monte Carlo (MC) and first-order second-moment (FOSM). With the above two reliability analysis methods, the calculations are carried out as follows: firstly, the non-Gaussian distribution of the grinding wheel based on Johnson Curves and filter techniques is established. Secondly, the results of the dynamic analysis are coupled into the grain trajectory equation. Thirdly, the influence of the wheel grinding parameters and dynamic parameters on the surface height is discussed by coupling the dynamic characteristics into the simulation model. Finally, the simulations and experiments are carried out on the impact of different feeding rates and sections on the workpiece to the surface heights. The comparisons verify the prediction of the simulation model. The obtained conclusions could be applied to optimize the workpiece’s topography by regulating the grinding parameters and dynamic parameters to weaken the chatter’s influence.