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Abrasive processes, commonly employed in manufacturing, are difficult to model because they rely on brittle particles with unknown geometry and multiple points of contact. Newly developed microreplicated abrasives allow for control of abrasive grit properties such as size, shape, and distribution. This paper proposes and validates a parametric model of abrasive machining that allows for studying the interaction of this particular tooling with randomly generated surfaces. In this work, the parameters of a probability distribution function that represents the workpiece surface are approximated by profilometry data. Monte Carlo simulation is used to account for inter- and intraspecimen variability. A geometric representation is used to mathematically represent the interaction between workpiece and tool. The results show good correlation between theoretical and actual values. This approach could be used to aid in tool geometry design as well as in process parameter optimization.


Copyright © 2012 Hitesh Kataria et al. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

Publication Title

Advances in Mechanical Engineering

Published Citation

Kataria, Hitesh, Andres L. Carrano, and Brian K. Thorn. “Modeling of Tooling-Workpiece Interactions on Random Surfaces.” Advances in Mechanical Engineering, (January 2012).



Peer Reviewed