Skip to main content
SpringerLink
Log in

Investigation on grinding temperature and heat flux distribution with grooved grinding wheels

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In order to enhance material removal rates without grinding burn, workpiece temperature and grinding heat flux were analyzed with grooved grinding wheels. The workpiece temperature distribution model for grooved wheels was established with the changed periodically heat source based on a constructed Green’s function. The heat flux partitioning model was obtained with considering grinding energy transferred to the workpiece, grinding wheel, chips, and coolant. Grinding experiments with grooved and non-grooved wheels were conducted at different feed rates to investigate the grinding performance of grooved structures. The workpiece temperature and grinding forces were measured to calculate the heat flux distribution based on the established models. Workpieces ground with grooved wheels kept a stable state without burn at feed rate of 400 ~ 3600 mm/min while workpieces ground with non-grooved wheels were burned at feed rate of 2400 mm/min, indicating that grooved grinding wheels can achieve a higher material removal rate without workpiece burn. Experiments and models indicated that the heat flux transferred to coolant with grooved grinding wheels was no more than that with non-grooved wheels. When the grinding zone temperature exceeded the boiling temperature of coolant, the workpiece ground with non-grooved wheels experienced a sharply increased force ratio, poor lubrication, and higher workpiece temperature, resulting in workpiece burn. The ratio of heat flux transferred to coolant and heat convection factor of coolant decreased quickly when the workpiece was burned. Grooved grinding wheels can help prevent workpiece burn due to the stable lubrication state and lower grinding forces.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17

Similar content being viewed by others

Abbreviations

x :

Grinding length

z :

Workpiece depth

x 0 :

Position in grinding contact length

c :

Specific heat capacity

ρ :

Density of workpieces

a :

Thermal diffusivity

λ :

Thermal conductivity of workpiece

λ s :

Thermal conductivity of abrasives

τ,\({\tau }^{^{\prime}}\) :

Time

g(x, z, τ):

Internal heat source

Q line :

Linear heat source

Q(x 0):

Heat source with non-grooved wheels

\(Q({x}_{0},{\tau }^{^{\prime}})\) :

Heat source with grooved wheels

G :

Green’s function

δ :

Unit pulse function

f(x, z):

Initial temperature distribution

v s :

Grinding speed

v w :

Feed rate

a p :

Depth of cut

d s :

Grinding wheel diameter

l c :

Grinding zone contact length

b :

Grinding width

Q w :

Material removal rate

q :

Total heat flux generated in the grinding zone

q w :

Mean heat flux transferred to the workpiece

q s :

Heat flux transferred to grinding wheels

q ch :

Heat flux transferred to chips

q f :

Heat flux transferred to coolant

q we :

Effective heat flux transferred to the workpiece in abrasive-workpiece contact area

R w :

Ratio of heat flux transferred to the workpiece

R ws :

Ratio of heat flux transferred to workpiece in workpiece-grinding wheels system

R f :

Ratio of heat flux transferred to coolant

h f :

Heat convection factor of coolant

η :

Area ratio of active wheel surface, groove factor

A 0 :

Total surface area of grinding wheels

A g :

Groove area along the wheel surface

T :

Intermittent period of heat source

N :

Groove number along the wheel circle

erf:

Error function

E :

Modification sequence of grooved heat source

r 0 :

Contact radius of abrasives in grinding zone

u ch :

Specific chip energy

θ :

Temperature rise

θ max :

Highest workpiece temperature rise

T max :

Highest workpiece temperature

T 0 :

Initial grinding temperature

T ch :

Melting temperature of chips

F t :

Tangential grinding force

F n :

Normal grinding force

F tc :

Tangential force in plowing plastic deformation and chip formation

F nc :

Normal force in plowing plastic deformation and chip formation

F tsl :

Tangential force in sliding process

F nsl :

Normal force in sliding process

μ :

Friction coefficient between the wear flat and workpiece

ε :

Force ratio

References

  1. Malkin S, Guo C (2007) Thermal Analysis of Grinding. CIRP Ann Manuf Technol 56:760–782. https://doi.org/10.1016/j.cirp.2007.10.005

    Article  Google Scholar 

  2. Heinzel C, Kirsch B, Meyer D, Webster J (2020) Interactions of grinding tool and supplied fluid. CIRP Ann Manuf Technol 69:624–645. https://doi.org/10.1016/j.cirp.2020.05.001

    Article  Google Scholar 

  3. Lavisse B, Lefebvre A, Torrance AA, Sinot O, Henrion E, Lemarié S, Tidu A (2018) The effects of the flow rate and speed of lubricoolant jets on heat transfer in the contact zone when grinding a nitrided steel. J Manuf Process 35:233–243. https://doi.org/10.1016/j.jmapro.2018.07.029

    Article  Google Scholar 

  4. Li HN, Axinte D (2016) Textured grinding wheels: A review. Int J Mach Tools Manuf 109:8–35. https://doi.org/10.1016/j.ijmachtools.2016.07.001

    Article  Google Scholar 

  5. Ding W, Linke B, Zhu Y, Li Z, Fu Y, Su H, Xu J (2017) Review on monolayer CBN superabrasive wheels for grinding metallic materials. Chin J Aeronaut 30:109–134. https://doi.org/10.1016/j.cja.2016.07.003

    Article  Google Scholar 

  6. Forbrigger C, Bauer R, Warkentin A (2017) A review of state-of-the-art vitrified bond grinding wheel grooving processes. Int J Adv Manuf Technol 90:2207–2216. https://doi.org/10.1007/s00170-016-9546-8

    Article  Google Scholar 

  7. Wu M, Guo B, Zhao Q (2018) Laser machining micro-structures on diamond surface with a sub-nanosecond pulsed laser. Appl Phys A 124:170. https://doi.org/10.1007/s00339-018-1594-5

    Article  Google Scholar 

  8. Mohamed A-MO, Bauer R, Warkentin A (2013) Application of shallow circumferential grooved wheels to creep-feed grinding. J Mater Process Technol 213:700–706. https://doi.org/10.1016/j.jmatprotec.2012.11.029

    Article  Google Scholar 

  9. Denkena B, Grove T, Göttsching T (2015) Grinding with patterned grinding wheels. CIRP J Manuf Sci Technol 8:12–21. https://doi.org/10.1016/j.cirpj.2014.10.005

    Article  Google Scholar 

  10. Hou Z, Yao Z, Sun Y, Shen H (2022) Grooving profile control for structured grinding wheels with picosecond pulsed laser. Int J Adv Manuf Technol 119:5851–5862. https://doi.org/10.1007/s00170-022-08655-w

    Article  Google Scholar 

  11. Guo B, Wu M, Zhao Q, Liu H, Zhang J (2018) Improvement of precision grinding performance of CVD diamond wheels by micro-structured surfaces. Ceram Int 44:17333–17339. https://doi.org/10.1016/j.ceramint.2018.06.197

    Article  Google Scholar 

  12. Walter C, Komischke T, Kuster F, Wegener K (2014) Laser-structured grinding tools – generation of prototype patterns and performance evaluation. J Mater Process Technol 214:951–961. https://doi.org/10.1016/j.jmatprotec.2013.11.015

    Article  Google Scholar 

  13. Brian Rowe W (2017) Temperatures in grinding—a review. J Manuf Sci Eng 139:121001. https://doi.org/10.1115/1.4036638

  14. Hou ZB, Komanduri R (2000) General solutions for stationary/moving plane heat source problems in manufacturing and tribology. Int J Heat Mass Transf 43:1679–1698. https://doi.org/10.1016/S0017-9310(99)00271-9

    Article  MATH  Google Scholar 

  15. Zhao Z, Qian N, Ding W, Wang Y, Fu Y (2020) Profile grinding of DZ125 nickel-based superalloy: grinding heat, temperature field, and surface quality. J Manuf Process 57:10–22. https://doi.org/10.1016/j.jmapro.2020.06.022

    Article  Google Scholar 

  16. Jaeger JC (1942) Moving sources of heat and the temperature at sliding contacts. J Proc R Soc New South Wales 56:203–224

    Google Scholar 

  17. Bei JY (1964) Analysis and research on grinding temperature. J Shanghai Jiao Tong Univ 55–71. https://doi.org/10.16183/j.cnki.jsjtu.1964.03.005

  18. Rowe WB, Jin T (2001) Temperatures in high efficiency deep grinding (HEDG). CIRP Ann 50:205–208. https://doi.org/10.1016/S0007-8506(07)62105-2

    Article  Google Scholar 

  19. Jin T, Rowe WB, McCormack D (2002) Temperatures in deep grinding of finite workpieces. Int J Mach Tools Manuf 42:53–59. https://doi.org/10.1016/S0890-6955(01)00094-3

    Article  Google Scholar 

  20. Hahn RS (1962) On the nature of the grinding process. Proc Third Int Mach Tool Des Res Conf:129–154

  21. Jin T, Stephenson DJ (2006) Analysis of grinding chip temperature and energy partitioning in high-efficiency deep grinding. Proc Inst Mech Eng Part B J Eng Manuf 220:615–625. https://doi.org/10.1243/09544054JEM389

    Article  Google Scholar 

  22. Miao Q, Li HN, Ding WF (2020) On the temperature field in the creep feed grinding of turbine blade root: simulation and experiments. Int J Heat Mass Transf 147:118957. https://doi.org/10.1016/j.ijheatmasstransfer.2019.118957

    Article  Google Scholar 

  23. Heinzel C, Kolkwitz B (2019) The Impact of fluid supply on energy efficiency and process performance in grinding. CIRP Ann - Manuf Technol 68:337–340. https://doi.org/10.1016/j.cirp.2019.03.023

    Article  Google Scholar 

  24. Dai C-W, Ding W-F, Zhu Y-J, Xu J-H, Yu H-W (2018) Grinding temperature and power consumption in high speed grinding of Inconel 718 nickel-based superalloy with a vitrified CBN wheel. Precis Eng 52:192–200. https://doi.org/10.1016/j.precisioneng.2017.12.005

    Article  Google Scholar 

  25. Lee KW, Wong PK, Zhang JH (2000) Study on the grinding of advanced ceramics with slotted diamond wheels. J Mater Process Technol 100:230–235. https://doi.org/10.1016/S0924-0136(00)00403-9

    Article  Google Scholar 

  26. Shi C, Li X, Chen Z (2014) Design and experimental study of a micro-groove grinding wheel with spray cooling effect. Chin J Aeronaut 27:407–412. https://doi.org/10.1016/j.cja.2013.07.013

    Article  Google Scholar 

  27. Pérez J, Hoyas S, Skuratov DL, Ratis YuL, Selezneva IA, de Córdoba PF, Urchueguía JF (2008) Heat transfer analysis of intermittent grinding processes. Int J Heat Mass Transf 51:4132–4138. https://doi.org/10.1016/j.ijheatmasstransfer.2007.11.043

    Article  MATH  Google Scholar 

  28. Zheng HW, Gao H (1994) A general thermal model for grinding with slotted or segmented wheel. CIRP Ann 43:287–290. https://doi.org/10.1016/S0007-8506(07)62215-X

    Article  Google Scholar 

  29. Kwak J-S, Ha M-K (2001) Force modeling and machining characteristics of the intermittent grinding wheels. KSME Int J 15:351–356. https://doi.org/10.1007/BF03185218

    Article  Google Scholar 

  30. Aslan D, Budak E (2015) Surface roughness and thermo-mechanical force modeling for grinding operations with regular and circumferentially grooved wheels. J Mater Process Technol 223:75–90. https://doi.org/10.1016/j.jmatprotec.2015.03.023

    Article  Google Scholar 

  31. Handa D, Kumar S, Babu Thekkoot Surendran S, Sooraj VS (2021) Simulation of intermittent grinding for Ti-6Al-4V with segmented wheel. Mater Today Proc 44:2537–2542. https://doi.org/10.1016/j.matpr.2020.12.626

    Article  Google Scholar 

  32. Fang C, Xu X (2014) Analysis of temperature distributions in surface grinding with intermittent wheels. Int J Adv Manuf Technol 71:23–31. https://doi.org/10.1007/s00170-013-5472-1

    Article  Google Scholar 

  33. Kirsch B (2017) The impact of contact zone flow rate and bulk cooling on the cooling efficiency in grinding applying different nozzle designs and grinding wheel textures. CIRP J Manuf Sci Technol 18:179–187. https://doi.org/10.1016/j.cirpj.2017.02.002

    Article  Google Scholar 

  34. Yang Q, Pu B (2001) Advanced heat transfer, 2nd edn. Shanghai Jiao Tong University Press, Shanghai

    Google Scholar 

  35. Cole K, Beck J, Haji-Sheikh A, Litkouhi B (2010) Heat conduction using greens functions, 2nd edn. CRC Press

    Book  MATH  Google Scholar 

  36. Zieniuk E, Sawicki D (2017) Modification of the classical boundary integral equation for two-dimensional transient heat conduction with internal heat source, with the use of NURBS for boundary modeling. J Heat Transf 139:081301. https://doi.org/10.1115/1.4036099

  37. Carslaw HS, Jaeger JC (1986) Conduction of heat in solids, 2nd ed. Clarendon Press, New York, Oxford Oxfordshire

  38. Malkin S, Guo C (2008) Grinding technology: theory and application of machining with abrasives. Industrial Press, New York

    Google Scholar 

  39. Qu S, Yao P, Gong Y, Yang Y, Chu D, Zhu Q (2022) Modelling and grinding characteristics of unidirectional C-SiCs. Ceram Int 48:8314–8324. https://doi.org/10.1016/j.ceramint.2021.12.036

    Article  Google Scholar 

  40. Garrity K (2000) NIST ITS-90 Thermocouple Database - SRD 60. National Institute of Standards and Technology. https://doi.org/10.18434/T4S888

  41. He B, Wei C, Ding S, Shi Z (2019) A survey of methods for detecting metallic grinding burn. Measurement 134:426–439. https://doi.org/10.1016/j.measurement.2018.10.093

    Article  Google Scholar 

  42. Li X, Chen Z, Chen W (2011) Suppression of surface burn in grinding of titanium alloy TC4 using a self-inhaling internal cooling wheel. Chin J Aeronaut 24:96–101. https://doi.org/10.1016/S1000-9361(11)60012-5

    Article  Google Scholar 

  43. Wang D, Sun S, Jiang J, Liu X (2017) The profile analysis and selection guide for the heat source on the finished surface in grinding. J Manuf Process 30:178–186. https://doi.org/10.1016/j.jmapro.2017.09.023

    Article  Google Scholar 

  44. Yi J, Jin T, Zhou W, Deng Z (2020) Theoretical and experimental analysis of temperature distribution during full tooth groove form grinding. J Manuf Process 58:101–115. https://doi.org/10.1016/j.jmapro.2020.08.011

    Article  Google Scholar 

  45. Aurich JC, Kirsch B (2013) Improved coolant supply through slotted grinding wheel. CIRP Ann - Manuf Technol 62:363–366. https://doi.org/10.1016/j.cirp.2013.03.071

    Article  Google Scholar 

Download references

Funding

The authors received support from the National Natural Science Foundation of China under the Grant No. U20A20284 and 52075323.

Author information

Authors and Affiliations

  1. State Key Laboratory of Mechanical System and Vibration, Shanghai, 200240, China

    Zhibao Hou & Zhenqiang Yao

  2. School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Zhibao Hou & Zhenqiang Yao

Authors
  1. Zhibao Hou
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Zhenqiang Yao
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Zhibao Hou involved in conceptualization, methodology, investigation, experimental measurement, data curation, and writing—original draft. Zhenqiang Yao involved in conceptualization, methodology, writing—review and editing, project administration, and funding acquisition.

Corresponding author

Correspondence to Zhenqiang Yao.

Ethics declarations

Competing interests

The authors declare no competing interests.

Additional information

Publisher's note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Hou, Z., Yao, Z. Investigation on grinding temperature and heat flux distribution with grooved grinding wheels. Int J Adv Manuf Technol 124, 3471–3487 (2023). https://doi.org/10.1007/s00170-022-10679-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-10679-1

Keywords

Search

Navigation