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Assessment of surface structure optimization in internal cooling grinding

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Abstract

For the purpose of solving the problems about grinding heat affecting workpiece surface quality during grinding Inconel 718, a novel internal cooling grinding wheel with phyllotaxis distribution of abrasive grain family is proposed in this paper. The coolant outlet shapes of replaceable abrasive ring are designed into waist-shaped and circular to investigate the influence of the surface structure on grinding performance. Then, CFD method is used to analyze the flow field distribution characteristics in grinding zone under different outlet shapes and rotation speeds. Finally, grinding experiments are carried out on Inconel 718. The simulation results reveal that the flow field distribution of the waist-shaped outlet is smoother and wider. The blind area of coolant is less that the maximum reduction is 54.61% compared with circular outlet. The increased rotation speed accelerates the flow rate of coolant at the outlet under the same outlet shape, without obvious effect on the fluid distribution range. The experimental results demonstrate that compared with the external flood cooling, internal cooling has excellent cooling and heat transfer capacity because of the avoidance of the air barrier effect. With the same internal cooling, the waist-shaped outlet has better grinding performance. When the rotation speed rises from 1000 to 3000 rpm, the maximum reduction of grinding temperature, surface roughness, and surface microhardness are 24.92%, 26.81%, and 4.09%, respectively. The maximum increase of surface residual compressive stress is 13.31% (about 80.73 MPa).

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Some data generated or used during the study are available from the corresponding author by request.

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Funding

This research has been supported by the National Natural Science Foundation of China (grant number 51975504, 51475404), the Provincial Natural Science Foundation of Hunan for Distinguished Young Scholars (grant number 2022JJ10045), and the Postgraduate Scientific Research Innovation Project of Hunan Province (grant number CX20210519, XDCX2022Y103).

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Authors and Affiliations

  1. School of Mechanical Engineering, Xiangtan University, Xiangtan, 411105, China

    Meiliang Chen, Ruitao Peng, Ao Li, Xiangwu Xiao & Linfeng Zhao

  2. Engineering Research Center of Complex Track Processing Technology & Equipment, Ministry of Education, Xiangtan University, Xiangtan, 411105, China

    Ruitao Peng

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  1. Meiliang Chen
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Contributions

Meiliang Chen performed the experiment and contributed significantly to analysis and manuscript preparation. Ruitao Peng contributed to the conception of the study. Ao Li conceived the conception of the study and was a major contributor in writing the manuscript. Xiangwu Xiao helped perform the analysis with constructive discussions. Linfeng Zhao participated in the experiment. All authors read and approved the manuscript.

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Correspondence to Ao Li.

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Chen, M., Peng, R., Li, A. et al. Assessment of surface structure optimization in internal cooling grinding. Int J Adv Manuf Technol 123, 2139–2155 (2022). https://doi.org/10.1007/s00170-022-10304-1

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