Investigation of different grain shapes and dressing to predict surface roughness in grinding using kinematic simulations

This paper presents a comprehensive study of a computationally efficient kinematic simulation to predict workpiece surface roughness in grinding using three different abrasive grain shapes (sphere, truncated cone, and cone) and a single-point diamond dressing model having both a ductile cutting and brittle fracture component. The resulting predicted workpiece surface roughness was experimentally validated for three different workpiece speeds, three different dressing depths of cut and three different dressing overlap ratios. For the surface grinding and single-point dressing conditions used in this research, the results showed that the dressing parameters used in the simulations supersede the assumed abrasive grain shape in their ability to influence the predicted workpiece surface finish. Furthermore, the corresponding average measured and predicted workpiece surface roughness agreed within approximately 7–11%.