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Analytical Modelling of Temperature in Cylindrical Grinding to Predict Grinding Burns

  • Azhar Thanedar
  • Ganesh G. Dongre
  • Suhas S. JoshiEmail author
Regular Paper
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Abstract

The direct measurement of grinding temperature is always difficult due to coolant cover and very size of work and wheel interaction zone. At the same time, high heat generation in grinding often leads to grinding burns thereby affecting surface integrity; in this context, theoretical evaluation of temperature could facilitate early detection of the grinding burns. This paper therefore presents an analytical model to evaluate grinding temperature and correlates it with the occurrence of grinding burns in terms of BNA. In general, the analytical approach involves evaluating real contact length, grinding forces and finally grinding zone temperature for the plunge cylindrical grinding. The maximum rise in grinding temperature at the surface was calculated, for the wet grinding process by considering the total heat flux entering into the grinding system. Model validation experiments have been performed to measure BNA and identify parametric conditions that produce grinding burns. The model estimate of grinding zone temperature of 631 °C is in good agreement (92%) with other research works. Further, when the calculated grinding temperature reaches beyond 631 °C, the grinding burns are observed on the work surface with a BNA value of the order of 100 mp for the micro alloyed steel. The minimum thermal damage in terms of BNA is observed at higher levels of wheel speed and spark-out time and lower levels of depth of cut.

Keywords

Cylindrical grinding BNA Grinding temperature Temperature analysis 

Abbreviations

D

Spherical grain diameter

Cd

Number of active grains per unit area

Cw

Specific heat density of work material

E1

Modulus of elasticity of work-piece

E2

Modulus of elasticity of grinding wheel

E*

Elastic properties of work-wheel

F

Friction coefficient between chip, grain, and the work-piece

Fn

Normal grinding force

\(F_{n}^{\prime }\)

Specific normal grinding force

\(F_{nchip}^{\prime }\)

Specific normal cutting force

\(F_{nslide}^{\prime }\)

Specific normal sliding force

\(F_{nplough}^{\prime }\)

Specific normal ploughing force

HB

Brinell hardness number of the work-piece

L

Paclet number

M

Size of an abrasive grain mesh size

Ra

Surface roughness

RL

Contact length ratio

Rr

Roughness factor

Rws

Work-wheel fraction

Tch

Chip temperature

Vs

Wheel velocity

Vw

Work velocity

ae

Depth of cut

b

Impression diameter

bw

Width of grinding

dg

Equivalent diameter of abrasive grain

de

Equivalent diameter of grinding wheel

df

Dynamic factor

ds

Diameter of grinding wheel

dw

Diameter of work-piece

fa

Fraction of abrasive grain that actively cut in grinding

h

Average un-deformed chip thickness

hf

Fluid convection factor

kw

Thermal conductivity

lc

Real contact length

lfr

Rough length of contact due to deflection

lfs

Smooth length of contact due to deflection

lg

Geometric length of contact

nw

Work-piece speed

qch

Specific chip heat flux

qf

Specific coolant heat flux

qt

Total heat flux

vr

In-feed

v1

Poisson’s ratio of workpiece

v2

Poisson’s ratio of grinding wheel

α

Thermal diffusivity

βw

Material thermal property

ρw

Density of work material

θm

Maximum rise in surface temperature

ε

Fraction of energy entering into the work surface

δ

Deflection due to normal grinding force

Ø

Approach angle

Notes

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Copyright information

© Korean Society for Precision Engineering 2019

Authors and Affiliations

  • Azhar Thanedar
    • 1
  • Ganesh G. Dongre
    • 2
  • Suhas S. Joshi
    • 3
    Email author
  1. 1.Kalyani Centre for Technology and InnovationBharat Forge Ltd.PuneIndia
  2. 2.Department of Industrial and Production EngineeringVishwakarma Institute of TechnologyPuneIndia
  3. 3.Department of Mechanical EngineeringIndian Institute of Technology BombayPowai, MumbaiIndia

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