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

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

Zi-Shan Ding , Yun-Hui Zhao , Miao-Xian Guo , Wei-Cheng Guo , Chong-Jun Wu , Steven Y. Liang

Advances in Manufacturing ›› 2023, Vol. 11 ›› Issue (3) : 428 -443.

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Advances in Manufacturing ›› 2023, Vol. 11 ›› Issue (3) : 428 -443. DOI: 10.1007/s40436-023-00436-2

Article

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

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¹ School of Mechanical Engineering, University of Shanghai for Science and Technology, 200093, Shanghai, People’s Republic of China

² College of Mechanical Engineering, Donghua University, 201620, Shanghai, People’s Republic of China

³ George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, 30332, Atlanta, USA

^c guomx@usst.edu.cn

Zi-Shan Ding is now an associate professor at University of Shanghai for Science and Technology. She received her doctorate from Donghua University. She has been a visiting scholar at the Georgia Institute of Technology. She is a senior member of the Chinese Society of Mechanical Engineering. Her research interests include grinding mechanisms, grinding residual stress and grinding processing. She has previously completed projects including the National Natural Science Foundation of China and has published over 30 research articles in international journals.

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Yun-Hui Zhao is a candidate of Master at University of Shanghai for Science and Technology. His main direction of scientific activity is cutting mechanism of hard-to-machine materials in grinding. His current research interests include green manufacturing and intelligent manufacturing.

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Miao-Xian Guo received the Ph.D. degree in mechanical engineering from Donghua University in 2016. He is now an Associate Professor at University of Shanghai for Science and Technology. His research interests include high speed and high precision machining technology, dynamic performance analysis and optimization of manufacturing equipment.

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Wei-Cheng Guo is a lecturer at University of Shanghai for Science and Technology. He was also a visiting scholar in Purdue University. His current research interests include precision machining of aerospace difficult-to-cut materials and intelligent manufacturing. He is a senior member of the Chinese Mechanical Engineering Society. He has anticipated and obtained several National Natural Science Foundation of China grants and has published over 20 international journal articles.

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Chong-Jun Wu received the Ph.D. degree in mechanical engineering from Donghua University in 2017, and received the Hiwin Doctoral Dissertation Award in 2018. He worked as a postdoctoral researcher at Donghua University from 2017-2019. He is currently an Associate Professor at Donghua University. His research interests include machining mechanism and technology, optimization of manufacturing processes and equipment.

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Steven Y. Liang is Morris M. Bryan, Jr. Professor in Mechanical Engineering for Advanced Manufacturing Systems at Georgia Institute of Technology, USA. Dr. Liang's research interests focus on precision manufacturing processes in the context of modeling, monitoring, control, and optimization. Dr. Liang's research program has been sponsored largely by federal agencies, national laboratories, along with industry sectors of aerospace, automotive, and energy to provide fundamental science and engineering with tangible application relevance. He has published over 200 scientific papers in recent 3 years.

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Abstract

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.

Keywords

Grinding force / Grain size / Dislocation density / Iterative loop

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Zi-Shan Ding, Yun-Hui Zhao, Miao-Xian Guo, Wei-Cheng Guo, Chong-Jun Wu, Steven Y. Liang. An iterative blending integrating grinding force model considering grain size and dislocation density evolution. Advances in Manufacturing, 2023, 11(3): 428-443 DOI:10.1007/s40436-023-00436-2

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Funding

National Natural Science Foundation of China http://dx.doi.org/10.13039/501100001809(52275453)

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