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Grinding of metals is a complex material removal operation involving cutting, ploughing, and rubbing depending on the extent of interaction between the abrasive grains and the workmaterial under the conditions of grinding.

Simulation shows that the proposed method yields the results that are consistent with measurement, thereby proving the effectiveness of the method. Furthermore, a truncated Gaussian distribution model is developed to relate the wheel volume wear to the change in the mean value of the protrusion heights. To determine the final profile considering thousands of the grains, a search method is developed to systematically solve the workpiece profile, starting with the highest protruded grain in a descending order of the grain protrusion heights. To solve this problem, first the intersecting points of any two grains with different heights are determined. As such, there is no formula, and a numerical solution is developed. To overcome this problem, the proposed method takes into consideration the random distribution of the grain protrusion heights. However, the analytical value based on the formula is substantially smaller than measurement. The conventional method determines the surface roughness based on the model using the mean value of the grain protrusion heights, which leads to a formula.

A new method for predicting the surface roughness of the workpiece for the grinding process is developed in this paper.