Abstract
This paper aims to clarify comprehensively and quantitatively the effects of elastic deflection between wheel and workpiece, wheel wear and thermal deformation of workpiece on the profile and dimensional errors of workpiece which is produced in one pass creep feed grinding. The elastic deflection is determined from the experimentally obtained static stiffness between wheel and workpiece during grinding. Effects of grinding conditions on the wheel wear are examined experimentally, and it is shown theoretically and experimentally that the radial wheel wear depends almost solely on the metal removal. Workpiece temperature distribution is analyzed by using the finite element method and it is revealed to agree with the experimental result. From this the thermal deformation is calculated by the FEM. It is shown that the resultant errors coincide well with the actual profile and dimensional errors of workpieces. Effects of profiled wheel wear and the thermal deformation of workpiece being profile ground are also considered.
