The morphologies of particles generated during the grinding of metals are analyzed. The ground materials include several steels, titanium, and copper while aluminum oxide, cubic boron nitride, and diamond abrasive grinding wheels are used. Interest is focused on spherical particles of which three distinct morphologies have been typically observed. The occurrence of these particles is related to the different grinding induced temperatures and arguments are advanced to suggest that the spherical particles are formed by frictionally induced melting and subsequent solidification. Finally, it is suggested that analysis of chip morphology may afford a simple means of determining whether the grinding process is thermally “out of control.”.
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