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ABSTRACT
The single grit cutting test was regarded as an important approach for understanding a complex grinding process, and revealed the connection between grinding wheel state, grinding parameters, and the surface integrity of workpieces. To investigate the formation mechanisms and morphology of grinding chips of 20CrMnTi steel, experiments on the high-speed grinding of a single grit on the surface of 20CrMnTi steel were performed by the finite element method. Combining this with the analysis of scratch morphology and the use of the finite element method, the authors showed that the process included sliding friction, ploughing, and produced fragmented, and continuous chips which changed with the cutting depth. Moreover, the distributions of physical quantities including stress, strain, heat, and temperature fields in the three areas subjected to cutting deformation were analyzed in greater detail. Moreover, combined with the deduced theoretical formulae, finite element simulation tests were conducted to analyze the undeformed chip thickness, shear angle, chip shape, strain in the formation process of chips from a single grit grain, and its changes with grinding parameters and the shape of abrasive grains.