Simulation analysis on cutting forces based on surface topography of fixed abrasive wire saw

Abstract Similar to grinding, a large number of diamond abrasive particles are used on the wire saw surface to remove materials by interaction with the workpiece. Therefore, the surface morphological characteristics of the wire saw, such as particle size and cutting edge height, have important effects on cutting performance of the wire saw. In terms of the complex diversity of the geometric characteristics and the randomness of the spatial position of the abrasive particles on the wire saw, the irregular polyhedron generated by the random space plane sphere method is used to simplify the abrasive particles and the space coordinates of the abrasive centre are created by random algorithm. As a result, a more realistic 3D model of the wire saw surface is constructed. A finite element method was employed to establish a cutting force simulation model of the wire saw with multiple abrasive particles for hard and brittle materials cutting processing, and the influence of feed rate and wire saw speed on cutting force was analysed; Based on the contact arc length, the cutting force model of multiple abrasive particles is extended to the macro level of wire saw cutting, and the reliability of the proposed model is verified by 4H-SiC cutting experiments. The established finite element model for microscopic simulation of the cutting process lays a foundation for cutting force prediction, tool parameter optimization and further research on wire saw cutting mechanism.