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<p>This study explores the grinding processes of bidirectional carbon–carbon (C/C) composite materials using a three-axis CNC machine. It systematically analyzes how layer orientation, workpiece speed, and tool speed affect grinding forces, chip formation, and tool loading. A piezoelectric dynamometer is employed for precise measurements of normal and tangential forces during grinding. Predictive models developed using response surface methodology show strong accuracy, with R<sup>2</sup> values of 0.94 and 0.97 for normal and tangential forces, respectively. The results reveal that optimal layer orientations (0°, 90°) significantly reduce grinding forces, while higher wheel speeds improve chip evacuation, thus decreasing forces. Conversely, forces increase with workpiece speed due to chip dynamics and tool wear. The study also identifies key mechanisms affecting tool loading, providing insights into grinding efficiency and tool longevity in industrial applications.</p>

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Parametric Analysis of Grinding Forces in Bidirectional C/C Composites: A Response Surface Approach

  • 期刊论文

  • 发表日期：

    2025年7月13日

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  • Hossein Lexian,
  • Javad Gholampour Darzi,
  • Mohammad Hossein Alaei,
  • Seyed Ali Khalife Soltani

摘要

This study explores the grinding processes of bidirectional carbon–carbon (C/C) composite materials using a three-axis CNC machine. It systematically analyzes how layer orientation, workpiece speed, and tool speed affect grinding forces, chip formation, and tool loading. A piezoelectric dynamometer is employed for precise measurements of normal and tangential forces during grinding. Predictive models developed using response surface methodology show strong accuracy, with R2 values of 0.94 and 0.97 for normal and tangential forces, respectively. The results reveal that optimal layer orientations (0°, 90°) significantly reduce grinding forces, while higher wheel speeds improve chip evacuation, thus decreasing forces. Conversely, forces increase with workpiece speed due to chip dynamics and tool wear. The study also identifies key mechanisms affecting tool loading, providing insights into grinding efficiency and tool longevity in industrial applications.