Papers by Author: Xue Kun Li

Abstract: The grinding process can be considered as micro-cutting processes with irregular abrasive grains on the surface of grinding wheel. Single grain cutting simulation of AISI D2 steel with a wide range of cutting parameters is carried out with AdvantEdgeTM. The effect of cutting parameters on cutting force, chip formation, material removal rate, and derived parameters such as the specific cutting force, critical depth of cut and shear angle is analyzed. The formation of chip, side burr and side flow is observed in the cutting zone. Material removal rate increases with the increase of depth of cut and cutting speed. Specific cutting force decreases with the increase of depth of cut resulting in size effect. The shear angle increases as the depth of cut and cutting speed increase. This factorial analysis of single grain cutting is adopted to facilitate the calculation of force consumption for each single abrasive grain in the grinding zone.

Abstract: Grinding is regarded as a special multiple edge cutting process, which can be decomposed into grain-workpiece interface, chip-workpiece/bond interface, and bond-workpiece interface at microscopic level. The grain-workpiece interface, which resembles a micro-cutting process, directly modifies the workpiece surface and dominates all the output measures of a grinding process. Therefore, the study of the grain-workpiece interaction through micro-cutting analysis becomes necessary. As the emergence of the packaged FEM software for micro-cutting simulation, apart from single grit cutting test, it enables another qualitative and quantitative investigation method on grain-workpiece interface mechanism in an efficiency and effective manner. In this paper, the efficacy of the commercialized cutting simulation software Third Wave AdvantEdgeTM is evaluated, and the possibility of using AdvantEdgeTM for in-depth understanding of grain-workpiece interface as well as grinding process modeling is studied, too.