The prediction of cutting forces is critical for the control and optimization of machining processes. This paper is concerned with developing prediction model for cutting forces in micro-grinding. The approach is based on the probabilistic distribution of undeformed chip thickness. This distribution is a function of the process kinematics, properties of the workpiece, and micro-topography of the grinding tool. A Rayleigh probability density function is used to determine the distribution of the maximum chip thickness as an independent parameter. The prediction model further includes the effect of dressing parameters. The integration of the dressing model enables the prediction of static grain density of the grinding tool at various radial dressing depths. The tool deflection is also considered in order to account for the actual depth of cut in the modeling process. The dynamic cutting-edge density as a function of the static grain density, the local tool deflection, elastic deformation, and process kinematics can hence be calculated. Once the chip thickness is calculated, the single-grain forces for individual abrasive grains are predicted and the specific tangential and normal grinding forces simulated. The simulation results are experimentally validated via cutting-force measurements in micro-grinding of Ti6Al4V. The results show that the model can predict the tangential and normal grinding forces with a mean accuracy of 10% and 30%, respectively. The observed cutting forces further imply that the flow stress of the material did not change with changing the cutting speed and the cutting strain rate. Moreover, it was observed that the depth of cut and grinding feed rate had the same neutral effect on the resultant grinding forces.

切削力的预测对于控制和优化加工过程至关重要。本文涉及微细切削力预测模型的开发。该方法基于未变形切屑厚度的概率分布。这种分布是过程运动学，工件特性和磨具微观形貌的函数。瑞利概率密度函数用于确定最大切屑厚度的分布作为独立参数。预测模型还包括修整参数的影响。修整模型的集成使得可以预测各种径向修整深度下磨具的静态晶粒密度。为了考虑建模过程中的实际切入深度，还考虑了刀具偏斜。因此，可以计算出作为尖端静态晶粒密度，局部刀具偏斜，弹性变形和加工运动学的函数的动态尖端密度。一旦计算出切屑厚度，就可以预测单个磨粒的单颗粒力，并模拟特定的切向和法向磨削力。通过在Ti6Al4V的微研磨中进行切削力测量，对仿真结果进行了实验验证。结果表明，该模型可以预测切向磨削力和法向磨削力，平均精度分别为10％和30％。观察到的切削力进一步暗示了材料的流动应力不会随着切削速度和切削应变率的改变而改变。此外，观察到切削深度和磨削进给速度对所得磨削力具有相同的中性作用。