Wheel Regenerative Chatter of Surface Grinding

In this paper we present a comprehensive dynamic model that simulates surface grinding processes and predict their regenerative chatter characteristics. The model considers special aspects in surface grinding processes, such as interrupted grinding on a series of surfaces and step-like wheel wear along the axial direction due to crossfeed. A new theory for the wheel regenerative chatter mechanism, which describes the regenerative force as a function of not only the instantaneous chip thickness but also the distributed uneven grit wear/dullness, is introduced and applied in the model. Using the model, explanations are provided for those unrevealed wheel regenerative chatter phenomena observed from the experimental results in literature. The model is validated by comparing the simulated chatter frequencies and thresholds with the experimental results.