Modelling the effects of grinding wheel parameters on surface roughness during grinding of D2 steel

The research focused on the effects of abrasive type, grain size, and wheel structure on surface roughness during external cylindrical longitudinal grinding of D2 steel. Experimental research was conducted using a full factorial design. The measured surface roughness values, depending on the combination of input parameters, ranged from 0.22 to 1.31 μm, corresponding to ISO roughness grades N4 to N7. Among the factors examined, grain size had the most significant impact on surface roughness, followed by the type of abrasive, while the grinding wheel structure had the least effect. The best surface roughness is obtained by utilizing corundum with the highest aluminium oxide content as an abrasive, along with the smallest grain size and a dense structure of the grinding wheel. Additionally, modelling of the grinding process was performed. The validity of the obtained regression equation for predicting surface roughness was confirmed through five additional verification experiments, which supported the accuracy of the modelling.