Estimation of the Surface Roughness in Cylindrical Plunge Grinding Based on Material Removal Model

As an important variable of the grinding quality, the surface roughness is a variable often used to describe the performance of the finished part as well as to evaluate the competitiveness of the overall grinding system. Hence, the estimation of surface roughness can cater to the requirements of performance evaluation. A new surface roughness model for multi-infeed cylindrical plunge grinding based on the material removal rate is established by using the monitoring power signal. It shows that steady-state surface roughness and the change in surface roughness are related separately to the grinding wheel wear and the material removal rate, the relationships of which are investigated. A series of experiments was performed to verify that estimation algorithm of surface roughness is effective and repeatable in grinding process control. The results demonstrated that the roughness model is valuable for designing process parameters to achieve the grinding quality index and the process optimization.