Experimental study of newly structural design grinding wheel considering response surface optimization and Monte Carlo simulation

Abstract The grinding process has a great advantage during machining structures in brittle and hard materials. Under this circumstance, the new grinding wheel – cutting surface of grinding – was structurally re-designed, which enables to produce and apply any size of grinding tools. With this new designed grinding wheel, the influence of grit size, grit concentration, and type of bond as well as operation parameters on the material removal mechanisms was analyzed during the grinding of hard-brittle materials. So, it becomes a necessity that the grinding operation with its parameters must be optimized correctly to have good control over the productivity, quality, and cost aspect of the operation. Furthermore, to demonstrate the modeling and optimization of the grinding process using three approaches. First, multi non-linear regression (MNLR) based on Box-Behnken design (BBD) was used to determine the process model based on surface roughness. Then the grinding parameters were optimized considering response surface methodology (RSM). Finally, Monte Carlo simulations were found quite effective for identification of the uncertainties in surface roughness that could not be possible to be captured by deterministic ways.

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