Cup wheel grinding in high-precision manufacturing: multiscale modeling, process innovation and sustainable practices

Abstract Cup wheel grinding has emerged as a core technique in high-precision manufacturing, offering unique advantages in efficient material removal and the machining of complex surfaces. This review provides a comprehensive overview of theoretical advancements, process innovations, and industrial applications of cup wheel grinding over the past decades. The theoretical discussion centers on multiscale modeling of grinding forces and heat generation, the regulation of surface integrity under thermo-mechanical coupling, and predictive approaches for wheel wear and service life. Furthermore, this review highlights the intrinsic links between material removal mechanisms and the control of subsurface damage. Moreover, this paper explores the fabrication and dressing of cup wheels, multi-objective parameter optimization strategies, multi-physics-assisted grinding techniques, and green cooling and lubrication solutions for enhancing efficiency and quality. Representative industrial applications demonstrate the irreplaceable role of cup wheel grinding in aerospace, energy, transportation, semiconductor, and optical manufacturing. This review outlines future research directions, including multiscale micro/nano grinding modeling, sustainable monitoring, control strategies for green manufacturing, and the integration of physical models with data-driven intelligent manufacturing. In addition, this review aims to serve as a comprehensive reference for academic and industrial communities, driving innovation in cup wheel grinding technologies and new quality productivity.