Simulation and Experimental Verification of Grinding Forces in Profile Grinding of 18CrNiMo7-6 Steel

doi:10.12068/j.issn.1005-3026.2025.20249038

Abstract

Abstract:

In order to investigate the influence of process parameters on the grinding force in V-notch forming during cylindrical grinding of 18CrNiMo7-6 carburized steel， a cubic boron nitride （CBN） grinding wheel abrasive particle model composed of random polyhedra generated by cutting regular hexahedra with spatial random planes was constructed based on the machining process of fatigue specimens. A three-dimensional simulation model of V-notch forming during cylindrical grinding was established by using ABAQUS finite element simulation software. With the grinding wheel speed n_s， workpiece speed n_w， and radial feed speed v_r as independent variables， single-factor experiments were conducted to study the variation patterns of normal grinding force F_n and tangential grinding force F_t. The validity of the V-notch forming simulation model during plunge grinding was verified through forming grinding force experiments. The results indicate that the normal grinding force is consistently greater than the tangential grinding force， and compared with the workpiece speed and the radial feed speed， the influence of grinding wheel speed on grinding force is more significant. The simulation results agree well with experimental data， where the average errors for normal grinding force predicted by simulations of n_s， n_w， and v_r are 11.06%， 9.21%， and 10.77%， respectively， and those for tangential grinding force are 9.89%， 13.89%， and 15.55%， respectively.

Key words: 18CrNiMo7-6 steel, V-notch, forming grinding, finite element simulation, grinding force

CLC Number:

TG 580.1

Yin-xia ZHANG, Lan-fu LIANG, Zuo-peng SONG, Meng-qi LI. Simulation and Experimental Verification of Grinding Forces in Profile Grinding of 18CrNiMo7-6 Steel[J]. Journal of Northeastern University(Natural Science), 2025, 46(12): 85-93.

Figures/Tables 18

Fig.1 CBN abrasive particle model

Fig.2 Geometric diagram of grinding wheel model (unit:mm)

Fig.3 Simulated grinding wheel model

Fig.4 Mesh division of workpiece

Table 1 Chemical composition of 18CrNiMo7-6 steel (mass fraction)

C	Si	Mn	S	P	Cr	Ni	Mo	Fe
0.15~0.21	0.4	0.50~0.90	≤0.035	≤0.035	1.50~1.80	1.40~1.70	0.25~0.35	余量

Table 2 Basic physical parameters of CBN grinding wheel and workpiece materials

材料	弹性模量/GPa	泊松比	密度/(kg·m^-3)	硬度
CBN	706	0.15	3 450	8 000(HV)
18CrNiMo7-6	210	0.30	7 800	60(HRC)

Table 3 Parameter values of constitutive model for

参数	数值	参数	数值
$σ 0$ /MPa	263	D₁	0.05
B_m/MPa	624	D₂	0.80
C_m	0.017	D₃	-1.54
m	1.3	D₄	0.01
n	0.26	D₅	1

Table 3 Parameter values of constitutive model for

参数	数值	参数	数值
$σ 0$ /MPa	263	D₁	0.05
B_m/MPa	624	D₂	0.80
C_m	0.017	D₃	-1.54
m	1.3	D₄	0.01
n	0.26	D₅	1

Fig.5 Schematic diagram of friction contact zone between abrasive particles and workpiece

Fig.6 V-notch specimen

Fig.7 Measuring device for forming plunge grinding

Fig.8 Installation of force measuring instruments

Fig.9 Schematic diagram of force analysis

Table 4 Process parameters of single-factor experiment

序号	砂轮转速n_s/(r·min^-1)	工件转速n_w/(r·min^-1)	砂轮径向进给速度v_r/(mm·min^-1)
1	4 000,5 000,6 000,7 000,8 000	700	0.15
2	6 000	500,600,700,800,900	0.15
3	6 000	700	0.1,0.125,0.15,0.175,0.2

Fig.10 Stress distribution on workpiece obtained by V-notch’s cylindrical grinding simulation

Fig.11 Grinding force curves obtained from notch grinding simulation

Fig.12 Grinding force curves obtained from notch grinding experiments

Fig.13 Influence of different process parameters on grinding force

Fig.14 Comparison of simulated and experimental results of grinding force under different process parameters

References 25

[1]	Liao D， Zhu S P， Correia J A F O， et al. Recent advances on Notch effects in metal fatigue： a review［J］. Fatigue & Fracture of Engineering Materials & Structures， 2020， 43（4）： 637-659.
[2]	Witkin D B， Patel D N， Bean G E. Notched fatigue testing of Inconel 718 prepared by selective laser melting［J］. Fatigue & Fracture of Engineering Materials & Structures， 2019， 42（1）： 166-177.
[3]	Li Z L， Shi D Q， Li S L， et al. A systematical weight function modified critical distance method to estimate the creep-fatigue life of geometrically different structures［J］. International Journal of Fatigue， 2019， 126： 6-19.
[4]	Meng Q Y， Guo B， Zhao Q L， et al. Modelling of grinding mechanics： a review［J］. Chinese Journal of Aeronautics， 2023， 36（7）： 25-39.
[5]	Zhang Y B， Li C H， Ji H J， et al. Analysis of grinding mechanics and improved predictive force model based on material-removal and plastic-stacking mechanisms［J］. International Journal of Machine Tools and Manufacture， 2017， 122： 81-97.
[6]	Gao P E， Tian P E， Tang Z H， et al. Comprehensive review of simulation methods in grinding processes： models， mechanisms， applications， and future directions［J］. Journal of Metals， 2025，77（9）： 1-18.
[7]	高腾，李长河，张彦彬，等.纳米增强生物润滑剂CFRP材料去除力学行为与磨削力预测模型［J］.机械工程学报，2023，59（13）：325-342.
	Gao Teng， Li Chang-he， Zhang Yan-bin， et al. Mechanical behavior of material removal and predictive force model for CFRP grinding using nano reinforced biological lubricant［J］. Journal of Mechanical Engineering， 2023， 59（13）： 325-342.
[8]	Yang S Y， Liang R J， Chen W F， et al. Modelling and experiment for grinding forces of gear form grinding considering complete tooth depth engagement［J］. Proceedings of the Institution of Mechanical Engineers， Part B： Journal of Engineering Manufacture， 2022， 236（13）： 1738-1750.
[9]	Azizi A， Mohamadyari M. Modeling and analysis of grinding forces based on the single grit scratch［J］. The International Journal of Advanced Manufacturing Technology， 2015， 78（5）： 1223-1231.
[10]	Sun J， Wu Y H， Zhou P， et al. Simulation and experimental research on Si₃N₄ ceramic grinding based on different diamond grains［J］. Advances in Mechanical Engineering， 2017， 9（6）： 168781401770559.
[11]	Ding H H， Han Y C， Zhou K， et al. Grinding force modeling and experimental verification of rail grinding［J］. Proceedings of the Institution of Mechanical Engineers， Part J： Journal of Engineering Tribology， 2020， 234（8）：1254-1264.
[12]	刘超杰. 钛基复合材料高速磨削加工磨削力仿真分析［J］. 机械制造与自动化， 2019， 48（2）： 89-93.
	Liu Chao-jie. Simulation analysis of grinding force in high speed grinding of titanium matrix composites ［J］. Machine Building & Automation， 2019， 48（2）： 89-93.
[13]	王子乐. 18CrNiMo7-6钢外圆磨削仿真与试验研究［D］. 郑州：郑州大学， 2021.
	Wang Zi-le. Simulation and experimental research on cylindrical grinding of 18CrNiMo7-6 steel［D］. Zhengzhou： Zhengzhou University， 2021.
[14]	Fu P， Jiang C H， Ji V. Microstructural evolution and mechanical response of the surface of 18CrNiMo7-6 steel after multistep shot peening during annealing［J］. Materials Transactions， 2013， 54（12）： 2180-2184.
[15]	张银霞，杨鑫，原少帅，等.18CrNiMo7-6钢高速外圆磨削的残余应力［J］.中国机械工程，2021，32（5）：540-546.
	Zhang Yin-xia， Yang Xin， Yuan Shao-shuai， et al. Residual stress of high-speed cylindrical grinding of 18CrNiMo7-6 steel ［J］. China Mechanical Engineering， 2021，32（5）： 540-546.
[16]	Zhang Y X， Yuan S S， Yang X，et al.Dry hard turning versus grinding： the influence of machining-induced surface integrity on fatigue performance［J］.Coatings， 2023， 13：809.
[17]	马少奇. 18CrNiMo7-6钢外圆磨削力及表面完整性研究［D］. 郑州：郑州大学，2021.
	Ma Shao-qi. Research on grinding force and surface integrity of 18CrNiMo7-6 steel in cylindrical grind ［D］. Zhengzhou： Zhengzhou University， 2021.
[18]	吴少洋. 18CrNiMo7-6合金钢外圆及缺口磨削仿真研究与试验验证［D］. 郑州：郑州大学，2022.
	Wu Shao-yang. Simulation study and experimental verification of cylindrical and notch grinding of 18CrNiMo7-6 alloy steel ［D］. Zhengzhou： Zhengzhou University， 2022.
[19]	Li X K， Wolf S， Zhi G， et al. The modelling and experimental verification of the grinding wheel topographical properties based on the ‘through-the-process’ method［J］. The International Journal of Advanced Manufacturing Technology， 2014， 70（1）： 649-659.
[20]	Li C S， Sun L， Yang S， et al. Three-dimensional characterization and modeling of diamond electroplated grinding wheels［J］. International Journal of Mechanical Sciences， 2018， 144： 553-563.
[21]	张银霞，韩程宇，杨鑫，等. GCr15钢平面磨削力仿真分析与实验研究［J］. 表面技术， 2019， 48（10）： 342-348.
	Zhang Yin-xia， Han Cheng-yu， Yang Xin， et al. Simulation analysis and experimental research on surface grinding force of GCr15 steel［J］. Surface Technology， 2019， 48（10）： 342-348.
[22]	国家质量监督检验检疫总局，中国国家标准化管理委员会. 超硬磨料粒度检验：［S］. 北京：中国标准出版社，2016.
	General Administration of Quality Supervision， Inspection and Quarantine， Standardization Administration of the People’s Repubilc of China. Superabrasive—checking the grain size：［S］. Beijing： Standards Press of China，2016.
[23]	王栋，王建军，李宁. 外圆磨削18CrNiMo7-6表面完整性研究［J］. 重庆理工大学学报（自然科学版）， 2020， 34（4）： 76-86.
	Wang Dong， Wang Jian-jun， Li Ning. Study on surface integrity of cylindrical grinding 18CrNiMo7-6［J］. Journal of Chongqing University of Technology （Natural Science）， 2020，34（4）： 76-86.
[24]	Johnson G R， Cook W H. Fracture characteristics of three metals subjected to various strains， strain rates， temperatures and pressures［J］. Engineering Fracture Mechanics， 1985， 21（1）： 31-48.
[25]	Özel T. The influence of friction models on finite element simulations of machining［J］. International Journal of Machine Tools and Manufacture， 2006， 46（5）： 518-530.