Mechanical behavior and modeling of grinding force: A comparative analysis

The grinding force is a crucial indicator of material removal process, which directly affects machining efficiency, surface quality and tool life. The force model, which plays a significant role for the application of grinding in various fields, is the most straight forward and comprehensive mathematical expression to describe the mechanical behavior of material removal. However, current research primarily focuses on modeling of grinding force in simple processes and materials, lacking systematically analysis including tools, processes and materials. To fill this gap, this paper aims to present a comprehensive analysis of material removal behavior and review of grinding force models to support valuable insights and knowledge for advanced grinding technology. Firstly, the development history of material removal constitutive model was reviewed and constitutive parameters are summarized based on the mechanical properties, strains and strain rates of five types of material. Secondly, the behavioral change phenomenon of material removal from rubbing, ploughing to cutting was analyzed considering speed effect, size effect, tribological and thermal impact. Finally, the modeling of maximum undeformed cutting thickness and dynamic active abrasives were summarized, based on the effect of grinding processes to geometry and kinematics of the abrasives. This paper provides valuable insights to scientists regarding the modeling of removal mechanisms and grinding forces for diverse materials, which can also serve as guidance for industrial production.