Evaluation of grindability of materials based on abrasive cutting simulation

The grindability of materials is investigated based on thermo-elastic plastic finite element simulations of orthogonal cutting with negative rake abrasive-grits. First the cutting mechanism of steel SK-5 with negative rake is clarified. In high speed grinding, adiabatic shear, which lead to serrated chip formation, is observed. Then the influence of material properties of SK-5 and cutting conditions on the cutting states are analyzed. Analysis shows a critical uncut chip thickness, under which chip forms with great difficulty. The critical uncut chip thickness changes complicatedly when material properties including the strain hardening exponent, yield stress, thermal conductivity, and initial temperature, are changed. Finally, grinding performance or grindability is evaluated by means of the critical uncut chip thickness and chip geometry.