OBRABOTKAMETALLOV technology Vol. 25 No. 4 2023 Both approaches are based on the energy balance proposed by S.N. Korchak on the equality of the energy expended to remove metal from the workpiece surface being machined by single abrasive grains and the grinding wheel as a whole (i.e. the equality of energy in terms of the volume of metal removed and the equality in the rate of stock removal). In a previous study [31], we considered in detail an algorithm of applying the second method to model the cutting force components based on the equal intensity of metal removal by the grinding wheel and the intensity of metal removal by cutting abrasive grains in the zone of contact with the workpiece. The equations of the cutting force model obtained by these two methods are identical. As a result, we can say that these analytical cutting force models, which are built on the assumptions and approaches from S.N. Korchak’s studies on the theory of cutting and plastic deformation of metal, are reliable regardless of the condition of equality of metal removal intensities or volumes. The resulting analytical model for calculating cutting force based on the equality of the removal rate and the volumes of removed metal by the wheel as a whole and by single grains in the zone of contact between the wheel and the workpiece was experimentally confirmed, which indicates its adequacy. Conclusions 1. The lack of adequate analytical models for calculating cutting force and depth for flat grinding in CAM systems from various manufacturers results in the need for manual selection of cutting conditions when an operation is designed. 2. The lack of systems for automatic calculation of cutting conditions for CNC flat grinding operations (digital tool for CAM systems) is a scientific and technical problem leading to the need to develop an analytical model of the cutting force that establishes a relationship between the force and the depth of the metal cut made by single grains with a stock removal and the cutting force that occurs during grinding with a wheel as a whole. 3. An analytical model for calculating the cutting force in flat grinding, which establishes the relationship of the cutting force with the cutting depth and the volumes of metal removed by single grains and the wheel as a whole based on the integration of microvolumes and microforces when the metal is cut by grains is proposed. 4. Mathematical modeling of the relationship between the cutting force and cutting conditions with the parameters of microcutting by a group of single grains was carried out, based on the equality of grinding energy when removing the same volume of metal. 5. The presented model of the cutting force occurring during flat grinding was confirmed experimentally and coincided with a model of cutting force which is also based on S.N. Korchak’s assumptions and the equal intensity of metal removal by the grinding wheel as a whole and by single grains in the contact zone of the wheel with the workpiece. 6. A practical application of the developed cutting force model will be the creation of a digital twin of flat grinding, which can predict the stability of the machined surface accuracy and quality and support optimization of designed operations, requiring the selection of the optimal cycles of cutting conditions and other input parameters (for example, the specifications of the abrasive tool), which is of great practical importance for the digitalization of engineering processes. References 1. Korchak S.N. Proizvoditel’nost’ protsessa shlifovaniya [Productivity of the grinding process]. Moscow, Mashinostroenie Publ., 1974. 280 p. 2. Zubarev Yu.M., Priemyshev A.V. Teoriya i praktika povysheniya effektivnosti shlifovaniya materialov [Theory and practice of improving the efficiency of materials grinding]. St. Petersburg, Lan’ Publ., 2010. 304 p. ISBN 9785-8114-0973-0. 3. Filimonov L.N. Vysokoskorostnoe shlifovanie [High-speed grinding]. Leningrad, Mashinostroenie Publ., 1979. 248 p.
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