SUMMARY

Modeling the surface finish in the grinding process is a difficult task due to the stochastic nature of the size, shape and spatial distribution of abrasive grains that make up the surface of grinding wheels. Since the surface finish obtained in grinding is a direct function of the wheel surface topography, which is conditioned by a single point dressing process, understanding the effects of dressing parameters on the wheel topography is essential. In this research, new experimental measurement and three-dimensional modeling techniques will be employed to accurately model the effects of dressing depth of cut and lead on the grinding wheel surface topography. Specifically, three-dimensional characterization of the grinding wheel topographical features such as the distribution of grain size, grain spacing, and grain protrusion will be done using a non-contact three-dimensional optical surface characterization instrument. From this data, statistical distributions for the key parameters (e.g. grain height, number of sides, grain spacing) necessary to describe the wheel surface topography will be determined. Single point dressing experiments will be conducted to evaluate and understand the effects of the dressing depth of cut and lead on the key wheel surface parameters. The research will also address the development of a three-dimensional geometric model to accurately describe the wheel surface topography prior to and after dressing. The resulting model will be validated by comparing simulated wheel surface topography parameters with measurements for different dressing conditions.