Optimization of edge grinding process based on stress-strength induced boundary effect

Abstract

Grinding damage of a ceramic edge directly impacts subsequent machining efficiency and part service life. Edge damage suppression is one of the key research issues in ceramic processing. However, there is still a lack of optimization methods for edge quality control due to the complicated interaction between abrasives and edges. In this paper, the influence of abrasive movement direction on the boundary damage is investigated by scratch test. The export damage measurement is noticeably more severe than at the import, and the rate of change in export force is higher than at the import level. A stress-strength induced boundary effect is proposed and analyzed by FEM-SPH to explain the edge removal mechanism, indicating asymmetric coupling between the stress field and mechanical strength in edge grinding. Hence, an edge processing optimization method with import grinding is proposed. The method uses a tilted workpiece and a dressed wheel to achieve import-side contact and export-side separation. This method can improve edge quality and represent stability under different parameters. Experiments demonstrate that import grinding can reduce edge roughness by 50 %. This study has practical significance for understanding the mechanism of edge removal and optimizing the edge grinding process of hard and brittle materials.