Abstract: A modeling method of abrasive grains is studied in this paper taking into consideration their irregular geometry and inconsistent size. Abrasive grains in the shape of irregular polyhedrons are modeled by cutting regular hexahedrons with random space planes.Their geometric features are similar to those observed in natural abrasive grains. Based on the LS-DYNA software, the cutting process of irregular polyhedral abrasive grains is simulated by the fluid-solid interaction method. According to the stress distribution and deformation law of workpiece materials, it can be seen that the machining stresses of a workpiece material mainly concentrate on the areas which are in contact with the cutting edges and cutting points of the abrasive grains. Chips flow upward along the extrusion face of the abrasive grains, and finally flow out in the normal direction. An increase of the rake angle of abrasive grains is helpful to chip formation. Scratching processes of abrasive grains are experimented by vitrified bonded CBN blocks. The validity of the simulation is verified by experiment results.

Key words: grinding, abrasive grain, modeling, cutting simulation, fluid-solid interaction