Study on the influence of orderly arrangement on grinding force in diamond roller dressing process

The diamond roller plays a crucial role in the formation and dressing of grinding wheels, with its abrasive wear being a significant factor that affects both the roller's lifespan and the quality of dressing. Effective arrangement of abrasive particles can help reduce this wear. However, current research primarily focuses on studying the impact of abrasive layout on single-layer grinding wheels, which limits its applicability to abrasive accumulation grinding wheels. This paper investigates how the arrangement of abrasive grains influences the process of dressing a grinding wheel. By employing finite element simulation and experimental verification during the forming and dressing processes using three types of roller arrangements (dislocation, array, and phyllotactic pattern), we evaluate their effects on grinding force as our main indicator. Our findings reveal that during the wheel dressing process, regular particle arrangement significantly impacts grinding force; specifically, array arrangement results in higher forces compared to dislocation arrangement while phyllotactic pattern yields lower forces. Furthermore, when compared to dislocation and array arrangements, phyllotactic pattern arrangement effectively reduces abrasion on the roller surface while enhancing both dressing performance and service life.