The instantaneous energy consumption in the grit-material interaction zone is an important indicator to represent the efficiency of grinding. In contrast to methods based on chip crack and formation or energy consumption from experimental measurement, this paper presents an improved differential model of energy consumption that takes account of dynamic grinding force, forced-vibration induced by the eccentrically grinding wheel rotation, and the phase difference between adjacent regenerative surface waviness. Furthermore, the vibratory amplitude and relevant frequency elements of a wheel-workpiece coupled system are analysed to optimize the key machining conditions involved in spindle speed, pack density of abrasive wheel and effective cutting space of adjacent contour grits in discrete transverse plane. It demonstrates that machining stability is the best when the phase difference value is π/2 between continuously formed adjacent waviness generated by grit-workpiece interaction, i.e. the calculated value of instantaneous grinding energy consumption reaches its maximum value. In comparison to stable situations, an unstable grinding process is excited when the phase difference value is 3π/2, i.e. micro-grinding force and vibration reinforce each other. It proves that a satisfied and stable grinding process can be controlled in real-time or in-situ by means of utilizing combination of optimal parameters, such as spindle speed, effective pack density, and the cutting space of abrasive grits. The presented mechanism is practical and can provide good guidance for further studies on machine-tool dynamics, time-domain or frequency-domain analysis of grinding vibration, and then on depth distribution of cut and ground surface accuracy.
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