Visual Simulation of Grinding Process

Grinding is one of the machining methods for finishing that is performed by using a large number of abrasive grains with irregular shapes and random distribution. While this feature enables accurate and high quality machining, it complicates analysis of the grinding process. In order to solve this problem, several computer simulations have been carried out using the Monte Carlo Method. Most of them statically calculate geometric interference between a grain and a workpiece, and have not provided enough achievements for practical applications. This chapter outlines the development of a simulation program based on the elastic behavior model of a grain. The program focuses on the generation process of a workpiece surface, and simulates the interaction of grains with a workpiece, which includes the elastic and plastic deformation and the removal of workpiece material. The simulation result is visualized using a three-dimensional graphics technique. The chapter illustrates an example, which verifies that the simulation program makes it easy to analyze the microscopic grinding phenomena, and can be used as a practical tool for predicting the grinding results and for optimizing grinding parameters. © 2006