Stress distributions at the abrasive-matrix interface during tool wear in bound abrasive grinding—a finite element analysis

• Published in: Wear Vol. 209; no. 1; pp. 247 - 254
• Main Authors: Zhou, Y., Funkenbusch, P.D., Quesnel, D.J.
• Format: Journal Article
• Language: English
• Published: Lausanne Elsevier B.V 01.08.1997; Amsterdam Elsevier Science; New York, NY
• Subjects: Applied sciences; Exact sciences and technology; FEA; Grinding; Interface; Mechanical engineering. Machine design; Stress; FEA; Grinding; Interface; Stress; Stress analysis; Tool material; Machining; Dispersion reinforced material; Two dimensional model; Numerical method; Composite material; Finite element method; Matrix fiber interface; Cutting tool; Abrasives; Abrasive machining
• ISSN: 0043-1648; 1873-2577
• DOI: 10.1016/S0043-1648(96)07490-X

In bound-abrasive grinding, the abrasive particles are subjected to normal and frictional forces due to their interactions with the workpiece. These forces generate stresses at the abrasive particle-matrix interface (also referred to as “the interface” in the following text). Debonding, or fallout of abrasive particles, will be affected by the stress state at the interface, which is determined by the load on the particle, the wear of matrix material around each individual particle, and the wear of the particle itself. A two-dimensional finite element model is established to calculate the stress distributions at the interface. Given the particle geometry and the load distributed around the abrasive tip, the calculations show that a high stress state occurs at the interface close to the surface of the matrix, i.e. the junction of the matrix surface and the interface. The magnitude of stress at the tension side of the particle increases drastically when the matrix is worn away evenly on both sides of the particle. However, wear of the bond along only the leading or tension side of the interface does not affect the stress distribution significantly. Wear of the abrasive particle itself has only limited influence on the stress distribution.