2D/3D ground surface topography modeling considering dressing and wear effects in grinding process

Roughness is usually regarded as one of the most important factors to evaluate the quality of grinding process and ground surface. Many grinding parameters are affecting ground surface roughness with different extents, however, the most influential factors are wheel dressing and wear effects which were unfortunately not get seriously attention in the previous researches. On the other hand, as a most common indicator, roughness is only a statistical evaluation which is not enough to describe the topography characteristics of a surface, especially under higher demands on grinding process and functional ground surface quality. Thus in this work, a 2D and 3D ground surface topography models were established based on the microscopic interaction mechanism model between grains and workpiece in grinding contact zone. In this study, besides grinding parameters, the wheel dressing and wear effects were taken into consideration, including dressing depth, dressing lead, geometry of diamond dressing tool and wear effects of both wheel and diamond dressing tool. A dressing and wear profile line, Ldw, which will describe how the grains’ shapes are changed, was established and added into a former 2D ground surface roughness prediction model. In order to obtain a better visual effect, a 3D topography model was established which is based on the interaction situations in real grinding process. Both 2D and 3D models will predict ground surface roughness more precisely and stably than traditional models by comparing with a dressing lead single-factor experiment. Results also showed that the selection of dressing parameters and dressing tools can refer to the formed shape of Ldw by comparing with grinding depth, ae, and the dressing lead should be carefully chosen which will greatly influence ground surface topography the most. •A new numerical method of ground surface roughness and 2D/3D topography considering dressing and wear effects was developed.•Most of the grinding and dressing parameters were considered; conclusions showed that dressing lead influents grinding process the most.•The method was validated by comparing with experiment; new method has more precise and stable prediction abilities.•The method developed and the calculation programs can be further used in dressing and grinding process design and optimization.