DIAGNOSTICS AND CONDITIONS FOR INCREASING THE EFFICIENCY OF THE GRINDING PROCESS BASED ON ENERGY PARAMETERS

Abstract

DOI: https://doi.org/10.26565/2079-1747-2025-36-02  

The aim of the work is to create a new theoretical approach to the diagnostics of the grinding process based on the separation of the share of friction energy of the grinding wheel with the processed material from the total energy balance of the grinding process and to establish under these conditions the directions for increasing its efficiency. For this purpose, the work establishes analytical dependencies for determining the energy parameters of the grinding process: the conditional cutting stress (processing energy intensity) and the grinding coefficient (the ratio of the tangential and radial components of the cutting force), which are inversely related to the conditional shear angle of the processed material. Based on this, calculations have proven that by reducing the experimentally established tangential component of the cutting force, it is always possible to achieve equality of the values ​​of the conditional shear angle of the processed material, which are determined by the conditional cutting stress and the grinding coefficient. Fulfillment of this condition ensures separation of the friction energy fraction of the grinding wheel with the processed material from the total energy balance of the grinding process, which is new in the theory of material processing by cutting. Calculations have established that during diamond spark grinding the friction energy fraction takes on a virtually zero value, since, due to the action of electric discharges in the cutting zone, a high cutting ability of the diamond wheel on the metal bond is ensured and its friction with the processed material is eliminated. A virtually zero value of the friction energy fraction was also obtained under the conditions of microcutting with a single diamond grain. All this indicates the reliability of the theoretical approach to the diagnostics of the grinding process proposed in the work. 

It was also established that under the conditions of conventional abrasive grinding, the share of friction energy can exceed the share of "clean" cutting energy. This is due to the low cutting ability of the abrasive wheel, since a significant part of the abrasive grains work only in the friction mode with the processed material. It is shown that the calculated values ​​of the friction coefficient and the grinding coefficient ("clean" cutting) differ little and actually correspond to the values ​​of the known ratio of the micro-cut thickness to the radius of the abrasive grain tip, at which the chip formation process in the cutting zone almost does not occur. In these cases, it is important to use effective methods of dressing and impregnation of grinding wheels, effective technological environments to increase their cutting ability. Therefore, knowledge of the actually established values ​​of the friction coefficient and the grinding coefficient ("clean" cutting) based on the proposed theoretical solution opens up new technological possibilities for increasing the efficiency of the grinding process and creating high-performance technological processes for processing machine parts.