Praveen Sridhar, Daniel Mannherz, Kristin de Payrebrune

• Grinding is one of the effective manufacturing processes with which to produce highly accurate parts with an ultra-fine surface finish. The tool used to remove materials in grinding is called the grinding wheel. Abrasive grains made of extremely hard materials (alumina, silica, cubic boron nitride, and diamond) having a definite grit size but a random shape are bonded on the circumferential surface of the grinding wheel. The fabrication process is controlled so that the wheel exhibits a prescribed structure (in the scale of soft to hard). At the same time, the distribution of grains must follow a prescribed grade (in the scale of dense to open). After the fabrication, the wheel is dressed to make sure of its material removal effectiveness, which itself depends on the surface topography. The topography is quantified by the distribution and density of active abrasive grains located on the circumferential surface, the grains’ protrusion heights, and their pore volume ratio. The prediction of the surface topography mentioned above requires a model that considers the entire manufacturing process and the influences on the grinding wheel properties. This study fills this gap in modelling the grinding wheel by presenting a surface topography model and simulation framework for the effect of the grinding wheel fabrication process on the surface topography. The simulation results have been verified by conducting experiments. This study will thus help grinding wheel manufacturers in developing more effective grinding wheels.