Structure-Coupled Modeling of Grinding Force for γ-TiAl Alloy Blade Tenon in Profile Grinding

The inherent brittleness and complex geometries of γ-TiAl alloy tenons introduce significant challenges for profile grinding, particularly in achieving accurate characterization of spatial load distribution. To overcome this limitation, a structure-coupled grinding force prediction model for grinding forces in profile grinding is proposed. This model discretizes the profile grinding wheel into multiple planar micro-elements via a dimensional approximation method, thereby quantifying the effective diameter at various contact positions. In addition, the model incorporates the effects of friction, elastic-plastic deformation, and brittle fracture. A weighting function is introduced to assess the competitive interaction among different material removal mechanisms within the grinding zone, and a genetic algorithm is employed to calibrate the correlation coefficients in the model. The experimental results show that the prediction error is less than 19.486%, which confirms the high accuracy and applicability of the model. Based on this foundation, the mechanism of the influence of local geometric features on the grinding force distribution and damage evolution is revealed by multi-scale characterization analysis, and a three-level mapping framework of “structural feature-grinding force-damage mechanism” is proposed and validated. This study elucidates the role of geometric complexity in grinding-induced mechanical response and damage evolution, and provides theoretical support for grinding force analysis in profile grinding of structurally complex components.