An iterative blending integrating grinding force model considering grain size and dislocation density evolution

The dynamic force load in grinding process is considered as a crucial factor affecting the quality of parts, and a better understanding of the mechanism of force generation is conducive to revealing the evolution of material microstructure more precisely. In this study, an iterative blending integrating grinding force model that comprehensively considers the impact of grain size and dislocation density evolution of the material is proposed. According to the grinding kinematics, the interaction of grit-workpiece is divided into rubbing, plowing, and chip formation stages in each grinding zone. On this basis, the evolution of material microstructure in the current chip formation stage will affect the rubbing force in the next grinding arc through flow stresses, which in turn will influence the total grinding force. Therefore, the flow stress models in rubbing and chip formation stages are firstly established, and then the dislocation density prediction model is established experimentally based on the characteristics of grain size. The effects of the evolution of grain size and dislocation density on the grinding forces during the grinding process are studied by means of iterative cycles. The results indicate that the implementation of an iterative blending scheme is instrumental in obtaining a higher accurate prediction of the grinding force and a deeper insight of the influence mechanisms of materials microstructure on grinding process.