Abstract: Grinding process can be considered as micro-cutting processes with irregular abrasive grits on the surface of grinding wheel. The study of the grit-workpiece interaction through single grit cutting is an important contribution to the explanation of the physical processes that occur during grinding. In this study, the mechanical and numerical simulation model of single grit cutting is built. The scratch tests with different load are performed to validate the mechanical and numerical simulation model. Single grit cutting with different process parameters (depth of cut, cutting speed) are modeled by finite element method (FEM) software AdvantEdge. The plowing and cutting processes during single grit cutting are simulated and the critical depth of cut from plowing to cutting is investigated. The simulated tangential and radial cutting forces increase sharply due to the pile-up of workpiece material in the front of single grit when the depth of cut reaches to some value. And the increase extent of cutting forces at low cutting speed is larger than that at high cutting speed. The simulated highest cutting temperature increase first, and then decrease, finally increase again with the increase of depth of cut. And the peak of simulated highest cutting temperature occurs near the critical depth of cut. Follow the decrease of cutting speed, this trend of highest cutting temperature falls down. When the cutting speed is lower than 600 m/min, this trend of highest cutting temperature does not exist. The simulated material removal rate increases with the increase of cutting speed and depth of cut.

Key words: Material removal rate, Critical depth of cut, Cutting temperature, Numerical simulation, Ratio of cutting force, Single grit cutting