Modeling of Grinding Force and Optimization of Groove Angles of Laser Grooved Grinding Wheels

doi:10.3969/j.issn.1004-132X.2026.08.005

Abstract

Abstract:

The influences of laser dressing parameters on abrasive morphology and protrusion height were studied. The influences of grooved grinding wheel surface topography on grinding force were analyzed， and the total grinding force model and the grinding force fluctuation model were established. The correlation law among groove pattern and groove angle and grinding force fluctuation was explored， and groove angle was optimized based on the principle of minimum grinding force fluctuation. The results show that the abrasive morphology after dressing is similar to the table shape， and the protrusion height of the abrasives is well fitted to the Rayleigh distribution function. When the grooving factor increases from 60% to 100%， the grinding force basically increases linearly. The average error between the predicted and experimental values of the total grinding force is about 5.55%. In the symmetrical straight groove grinding wheel， the grinding force fluctuation increases with the increase of the number of chutes in a single groove pattern. The grinding force fluctuation model is a discontinuous function with groove angle. Except for the optimized groove angle， the fluctuation of grinding force decreases with the increase of groove angle. The grinding force fluctuation of the groove angle optimized grinding wheel is minimal， and the surface roughness and surface damage of the workpiece are the least. The above model may accurately predict the grinding force of the laser grooved grinding wheels， help to optimize the groove angles of the grinding wheel surface， and improve the surface quality of the workpieces.

Key words: grinding force, laser grooving, grinding wheel morphology, grinding force model, grinding force fluctuation, groove angle optimization

摘要：

研究激光修整参数对磨粒形貌和出刃高度的影响规律，分析沟槽化砂轮表面形貌对磨削力的影响，建立总磨削力模型和磨削力波动模型；探索沟槽图案和槽角与磨削力波动的关联规律，基于磨削力波动最小原则对沟槽角度进行优化。研究结果表明：修整后磨粒形貌近似于圆台形，磨粒出刃高度与瑞利分布函数的拟合度较高；当沟槽因子从60%增至100%时，磨削力基本呈线性增加趋势，总磨削力的预测值与实验值的平均误差约5.55%；对称型直槽砂轮的磨削力波动随单个沟槽图案中斜槽数量的增大而增大；磨削力波动模型是随槽角变化的间断函数，除优化后的槽角外，磨削力的波动随槽角的增大而减小；槽角优化砂轮的磨削力波动最小，工件表面粗糙度与损伤最小。所建模型能较精确地预测激光沟槽化砂轮的磨削力，有助于优化砂轮表面沟槽角度、提高工件表面质量。

关键词: 磨削力, 激光沟槽化, 砂轮形貌, 磨削力模型, 磨削力波动, 沟槽角度优化

CLC Number:

TG743

DENG Hui, GUO Chunshan, YUCHI Guangzhi, WANG Qian, YI Jun. Modeling of Grinding Force and Optimization of Groove Angles of Laser Grooved Grinding Wheels[J]. China Mechanical Engineering, 2026, 37(8): 1852-1864.

邓辉, 郭春山, 尉迟广智, 王谦, 易军. 激光沟槽化砂轮磨削力建模及沟槽角度优化[J]. 中国机械工程, 2026, 37(8): 1852-1864.

Figures/Tables 25

Fig.1 Geometric morphology of abrasive grains

Fig.2 Schematic diagram of removal mechanism of ceramic materia

Fig.3 Random abrasive grains grinding depth diagram

Fig.4 Chip diagram of the grinding process and brittle removal of abrasive grains

Fig.5 Schematic diagram of chip morphology transformation

Fig.6 Schematic diagram of size of V-shaped wheel

Fig.7 The influence of three kinds of groove parameters on the effective contact width

Fig.8 Laser grooving experimental device

Tab.1 Laser dressing parameters

修整参数	激光整形	激光修锐
激光功率P_avg/W	70	12
脉冲频率f_p/kHz	50	100
扫描速度v_p/（mm·s $- 1$ ）	0.011	0.011
扫描次数		20，40，60

Tab.1 Laser dressing parameters

修整参数	激光整形	激光修锐
激光功率P_avg/W	70	12
脉冲频率f_p/kHz	50	100
扫描速度v_p/（mm·s $- 1$ ）	0.011	0.011
扫描次数		20，40，60

Tab.2 Laser grooving parameters

激光功率P_avg/W

脉冲频率f_p/kHz

扫描速度

v_p/（mm·s $- 1$ ）

扫描次数

250

1000

Tab.2 Laser grooving parameters

激光功率P_avg/W

脉冲频率f_p/kHz

扫描速度

v_p/（mm·s $- 1$ ）

扫描次数

250

1000

Fig.9 Three different patterns of grooved grinding wheels

Fig.10 Experimental device and force measuring system

Tab.3 Physical properties of zirconia ceramics

密度ρ/

（g·cm $- 3$ ）

弯曲强度

δ/MPa

维氏硬度H_V/

（GPa·m^1/2）

弹性模量

E/GPa

断裂韧性

K_IC/MPa

泊松比

Tab.3 Physical properties of zirconia ceramics

密度ρ/

（g·cm $- 3$ ）

弯曲强度

δ/MPa

维氏硬度H_V/

（GPa·m^1/2）

弹性模量

E/GPa

断裂韧性

K_IC/MPa

泊松比

≥6

≥1000

200

0.3

Tab.4 Grinding experimental conditions

砂轮速度v_s/

（m·s $- 1$ ）

磨削深度

d_g/μm

进给速度

v_f/（mm·min $- 1$ ）

Tab.4 Grinding experimental conditions

砂轮速度v_s/

（m·s $- 1$ ）

磨削深度

d_g/μm

进给速度

v_f/（mm·min $- 1$ ）

冷却液

15.7

5，10，15，20

500，1000，1500，2000

水基冷却剂（W20型）

Fig.11 Variation in the section width of abrasive grains

Fig.12 The proportion of new protruding and shedding abrasive grains

Fig.13 The fitting of the distribution of abrasive grains protruding height when scanning 20， 40 and 60 times

Fig.14 Side morphology of abrasive grains after laser dressing

Fig.15 Prediction and verification of grinding force under different grinding parameters

Tab.5 Error between predicted value and actual value

磨削参数		沟槽因子
磨削参数		60%	70%	80%	90%	100%
磨削深度d_g/μm	5	6.6	12.2	6.3	8.7	3.2
	10	4.8	4.2	3.5	5.3	4.9
	15	6.4	6.2	10.7	1.3	6.7
	20	1.6	1.6	7.0	7.2	2.1
进给速度 v_f/（mm·min $- 1$ ）	500	13.1	7.2	4.9	1.6	5.4
	1000	4.1	7.4	14.5	6.5	6.7
	1500	4.8	4.2	3.5	5.3	4.9
	2000	5.8	5.6	1.2	1.3	2.9

Tab.5 Error between predicted value and actual value

磨削参数		沟槽因子
磨削参数		60%	70%	80%	90%	100%
磨削深度d_g/μm	5	6.6	12.2	6.3	8.7	3.2
	10	4.8	4.2	3.5	5.3	4.9
	15	6.4	6.2	10.7	1.3	6.7
	20	1.6	1.6	7.0	7.2	2.1
进给速度 v_f/（mm·min $- 1$ ）	500	13.1	7.2	4.9	1.6	5.4
	1000	4.1	7.4	14.5	6.5	6.7
	1500	4.8	4.2	3.5	5.3	4.9
	2000	5.8	5.6	1.2	1.3	2.9

Fig.16 Relationship between grooving factor and grinding force

Fig.17 Influence of groove pattern on grinding force fluctuation

Fig.18 Influence of groove angle on grinding force fluctuation under different grinding parameters

Fig.19 Surface roughness under different groove angle

Fig.20 SEM diagram of workpiece surface morphology under different grinding conditions

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