Diamond grinding of cutting inserts: edge chipping, specific energy, wheel wear, and process optimization

Journal article, 2026

Diamond grinding of cutting-inserts was modeled and optimized by taking into account the varying position-dependent contact conditions along the nose radius. The results demonstrate that the dimensionless aggressiveness number correlates strongly with specific grinding energy and G-ratio while edge chipping along the nose radius shows no systematic dependence on process geometry and kinematics. A constant-aggressiveness grinding strategy, implemented by varying the insert angular speed, significantly reduces the total grinding energy and reduces the cycle time with no deterioration of edge quality. Overall, the developed physical models provide a robust, wheel-topography-independent framework for analyzing and optimizing grinding of cutting inserts.