Simulation of surface patterns imprinted by wheel grinding which dressed by rounded tools

Abstract

Surfaces having more precise pattern are effective for lubrication, friction or drag, being designed by engineers and incorporated into the components specification. Therefore, it is very important to develop such precise surface patterns in a repeatable and economically viable way. The aim of this research work is to develop rounded groove surface pattern model by grinding with the grooved wheel based on dressing. In order to grooving of grinding wheel, a rounded tip dresser is used instead of sharp tip dresser. The developed grooved wheel geometry model can be integrated with a grinding process model for simulating rounded groove surface patterns. A computer based simulation program is developed using Matlab according to proposed mathematical model to display 3D geometry of the patterned surface. The simulation results of resulting surface pattern with rounded groove can be realized by interactively inputting parameters in to the developed software. An experiment has been carried out for the verification of the simulation results and it is found that the simulation results agree well with the experiment. The simulation results could be used to predict the rounded groove surface patterns by the given grinding parameters.