Estimation of the Maximum Undeformed Chip Thickness in Grinding Based on Volume Balance of the Material Removed

In the analysis of grinding process, the maximum undeformed chip thickness is one of the most important parameters as in that of metal cutting process. In order to estimate the maximum undeformed chip thickness in grinding operation, it is necessary to obtain the successive cutting point spacing which is usually done by experimental grinding scratch tests. Using the average grain grinding model and based on volume balance of the material removed, it is possible to estimate the maximum undeformed chip thickness without using any experimentally obtained data. The validity of the proposed analysis has been verified based on two sets of grinding scratch tests using WA and CBN grinding wheels. The values of the estimated maximum undeformed chip thicknesses lie in the range of the experimentally obtained maximum undeformed chip thicknesses.