Multi-criteria Evaluation of Microcrystalline corundum grinding wheel: case study of centerless grinding production line of micro-motor rotor shaft

To address frequent dressing issues in centerless grinding of micromotor shafts, this study proposes replacing conventional corundum grinding wheel with microcrystalline corundum grinding wheel, thereby establishing a comprehensive evaluation model that integrates manufacturing efficiency, quality, and unit cost over the wheel’s service life. Experimental results demonstrate that microcrystalline corundum grinding wheel significantly outperform their conventional counterparts: they extend the dressing interval by 2.2-fold, increase production efficiency by 31.26%, improve workpiece roundness accuracy by 66%, and reduce unit cost by 42.2%. Sensitivity analysis confirms the potential for further cost reduction through wheel parameter optimization. Friction and wear tests reveal that microcrystalline corundum grinding wheel exhibit a lower friction coefficient and predominantly intergranular fracture. This fracture mode generates smaller abrasive debris, resulting in superior wear resistance and prolonged retention of cutting sharpness. Collectively, these properties enable microcrystalline corundum grinding wheel to effectively resolve the frequent dressing problem associated with traditional alumina wheels in micromotor shaft grinding. This study provides actionable, data-driven insights for optimizing industrial grinding processes.