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The instantaneous energy consumption in grit-material interaction zone is one of important indicators to represent the efficiency of grinding. In contrast to methods based on chip crack and formation or energy consumption from experimental measurement, this paper presents an improved differential model of energy consumption that takes account of dynamic grinding force, forced-vibration induced by the eccentrically grinding wheel rotation and the phase difference between adjacent regenerative surface waviness. Further, the vibratory amplitude and relevant frequency elements of wheel-workpiece coupled system are analyzed to optimize the key machining conditions that involve in spindle speed, pack density of abrasive wheel and effective cutting space of adjacent contour grits in discrete transverse plane. It demonstrates that machining stability is the best, when the phase difference is /2 between continuously formed adjacent waviness generated by grain-workpiece interaction, i.e. the calculated value of instantaneous grinding energy consumption reaches to its maximum value. In comparison to stable situations, an unstable grinding process is excited when the phase difference value is 3/2, i.e. micro-grinding force and vibration reinforce each other. It proves that a satisfied stable grinding process can be controlled in real-time or in-situ by means of utilizing combination of optimal parameters, such as spindle speed, effective pack density and cutting space of abrasive grits. The presented mechanism is practical and can provide a good guidance for further studies on machine tool dynamics, time-domain or frequency-domain analysis of grinding vibration, and then on depth distribution of cut and ground surface accuracy.

Effect of Energy Consumption in the Contact Zone on Machining Condition Optimization in Precision Surface Grinding