Influence of Grinding Wheel Microstructure on Material Removal Efficiency and Wheel Wear in High‐Pressure Grinding

High‐pressure grinding (HPG) is a key process for removing surface defects from continuously casted steel slabs, offering greater precision and repeatability than legacy scarfing methods. This study investigates the performance of three commercial Al 2 O 3 ‐based high‐pressure grinding wheels containing rod‐shaped abrasives (samples 1, 2, and 3) during industrial full‐scale grinding trials. Process parameters, including cutting depth, contact force, vibration, and grinding wheel diameter, were recorded across eight machining steps, revealing substantial differences in tool behavior despite identical nominal settings. Sample 1 achieved the highest material removal and the most favorable wear‐efficiency ratio ( V GW / V WP ), whereas sample 2 showed elevated wear and higher roughness. Sample 3 demonstrated moderate removal rates, stable forces, and intermediate wear behavior. Microstructural, chemical, and hardness analyses indicated that variations in ceramic particle size, matrix composition, and fiber reinforcement govern tool performance. Larger, harder grains in sample 2 enhanced cutting aggressiveness but reduced wheel life, whereas finer microstructures in samples 1 and 3 promoted smoother wear and improved process stability. An optimal grinding wheel angle of 70° was identified to balance energy efficiency, process stability, and tool wear. The results highlight the strong interplay between wheel microstructure, process parameters, and grinding efficiency in industrial HPG operations.