Analysis and simulation of double disc grinding

Double disc grinding is a high production process for generating parallel surfaces using opposing flat faces of bonded abrasive wheels. Although widely used for more than 75 years in the production of automotive, bearing, and compressor components requiring tight tolerances and fine finishes, no fundamental analysis has been reported for the process. This paper presents the development of a geometric and kinematic analysis for rotary carrier double disc grinding. Using the analysis, a simulation software package has been developed to quantitatively describe the grinding process as the part is fed between the wheels. The salient features of the package include calculation of the separation distance between the wheel faces, infeed and stock removal rates, wheel wear and its distribution, and grinding power. An example is presented to illustrate how the simulation works.