Study on influence of grinding depth and grain shape on grinding damage of K9 glass by SPH simulation

This work use the SPH method to study the relationship between grinding depth and grinding force of K9 glass in ultra-precision grinding, and the effect of grain shape on material removal. The relationship between the force and the depth in the stable scratching stage is F_R = 0.55078a_p^1.15356, which provides a basis for controlling the grinding depth by force. The material removal modes at different grinding depths were obtained, that is, plastic removal occurs below 0.2 μm, brittle transition occurs between 0.2 and 0.4 μm, and brittle removal occurs at more than 0.5 μm. It is found that the cutting resultant force of sharp grains is smaller and the normal force is smaller than the tangential force. By analyzing the plastic deformation depth and residual stress depth, it is found that the material removal mode with small deformation and little removal has the lowest cutting force fluctuation and the highest grinding quality. It provides a reference for the choosing of grain shape in rough grinding and ultra-precision grinding. The correctness and reliability of the simulation results were verified by the comparison of the simulation findings with the results obtained from varied-depth scratching experiments and the multi-shape indenter scratch experiments.