Roughness Generated in Surface Grinding of Metals

Abstract

When a metal is surface ground the roughness generated is the summation of a function of the wheel roughness and the roughness due to wheel attrition and damage to the workpiece. We identify this function here as a maximum envelope profile, which is fractal within certain cut off wavelengths determined by the dressing conditions of the wheel. Estimating the global displacement of the binder-grit-workpiece system from the maximum envelope power spectra, we determine the plastic indentation of the workpiece at characteristic length scales using simple contact-mechanical calculation. The estimated roughness corresponds well with that recorded experimentally for hard steel, copper, titanium and aluminium.