A Re-Examination of the Uncut Chip Model of Grinding and Its Practical Implications

The increasing use of grinding processes employing high rates of metal removal requires a means of predicting or explaining grinding performance in the high-rate regime of grinding. Formulae for uncut chip dimensions previously developed fail to take full account of infeed and workpiece speed effects especially at high rates of grinding. The uncut chip model is re-examined and a better formulation for uncut chip dimensions is proposed, based on the loci of pairs of adjacent cutting edges through a ‘stationary’ workpiece. This solution differs from previous formulations particularly at high-rates of grinding. Effects on grinding performance are predicted which have been indicated by high-rate grinding trials. The practical implications of the model are discussed.