Modeling and simulation of the advanced structured surfaces machined by specially patterned grinding wheels via the structuring grinding process

In this work, the ability to reshape the grinding wheels with patterns of special and modern geometries to produce the advanced structured surfaces is studied. Firstly, a mathematical model is built for the process relating the geometry of the grinding wheel, geometries of the wheel patterns, the produced structured surfaces, and the grinding operating parameters. Then, different regular and irregular geometries are designed to be patterned over the wheel surface. The regularly designed patterns include the circular, the elliptical, and the polygonal patterns, while the heart-like patterns are included as irregular ones. Afterward, a simulation method to express the patterned wheels and the corresponding structured surfaces at different working conditions is developed. The effects of the patterns’ geometries on the obtained structured surfaces at the selected working conditions are investigated. The results of the grinding operations designed and carried out experimentally reflect the dependability of the presented method for machining the advanced structured surfaces using the grinding processes.