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Analysis for green grinding of Ti-6Al-4V titanium alloys with profile rotating heat pipe-grinding wheel

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Abstract

Profile grinding of titanium alloys are now utilized for aero-engine structural components. However, owing to its low thermal conductivity, the grinding contact zone generates an intense deal of heat, resulting in burns on the surface of the workpiece. At the same time, titanium alloys are prone to abrasive adhesion at high temperatures, which aggravates the wear of the grinding wheel. A novel grinding wheel named profile rotating heat pipe-grinding wheel (PRHP-GW) was created to improve heat transfer in the grinding contact zone. Therefore, it is expected to achieve efficient heat exchange. The kind of working medium in the rotating heat pipe (RHP) is the key factor that might seriously influence the heat transmission capacity of the RHP-GW. In this article, the numerical simulation is applied to investigate the heat transfer characteristics of PRHP-GW from the perspective of different grinding heat flux, rotating speed and grinding wheel types (normal grinding wheel without RHP, PRHP-GW filled with deionized water, and PRHP-GW filled with diamond nanofluid). The results demonstrate that the heat transfer capacity of PRHP-GW is superior to that of the normal grinding wheel. In addition, the heat transfer performance of PRHP-GW filled with diamond nanofluid is better than the case filled with deionized water.

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Abbreviations

q total :

Total grinding heat flux, W/m2

F t :

Tangential grinding force, N

v s :

Grinding speed, m/s

a p :

Grinding depth, mm

l s :

Length of the grinding contact zone, mm

v w :

Workpiece feed rate, mm/min

Q total :

Total grinding heat, W

Q workpiece :

Grinding heat distributed in the workpiece, W

Q wheel :

Grinding heat distributed in the grinding wheel, W

Q chip :

Grinding heat distributed in chips, W

Q coolant :

Grinding heat distributed in the grinding fluid, W

ε :

Heat distribution ratio between the workpiece and the grinding wheel

c :

Specific heat capacity, J/(kg·K)

λ :

Thermal conductivity, W/(m·K)

q wheel :

Heat flux entering the grinding wheel, W/m2

h :

Equivalent heat transfer coefficient, W/(m2·K)

T e :

Average temperature of the evaporator section, K

T c :

Average temperature of the condenser section, K

k eff :

Equivalent thermal conductivity of the RHP, W/(m·K)

L e :

Length of the evaporator section, m

L ad :

Length of the adiabatic section, m

L c :

Length of the condenser section, m

A cr :

Cross-sectional area of the RHP, m2

R :

Thermal resistance of the RHP, K/W

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Funding

This work was supported by the National Natural Science Foundation of China [Grant No. 51905275, No. 52205476], Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology, the Natural Science Foundation of Jiangsu Province [Grant No. BK20190752], Outstanding Postdoctoral Program of Jiangsu Province (No. 2022ZB204), and China Postdoctoral Science Foundation ( No. 2022M721623, No. 2021M701696).

Author information

Authors and Affiliations

  1. College of Mechanical and Electronic Engineering, Nanjing Forestry University, Nanjing, 210037, China

    Liyong Zhang, Jiajia Chen, Huafei Jiang & Youlin Xu

  2. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Ning Qian, Yucan Fu & Yan Chen

  3. Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Yan Chen

  4. College of Mechanical and Electrical Engineering, Suzhou University of Science and Technology, Suzhou, 215009, People’s Republic of China

    Chenwei Dai

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  1. Liyong Zhang
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Liyong Zhang. The first draft of the manuscript was written by Liyong Zhang, and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Jiajia Chen.

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Zhang, L., Chen, J., Jiang, H. et al. Analysis for green grinding of Ti-6Al-4V titanium alloys with profile rotating heat pipe-grinding wheel. Int J Adv Manuf Technol 131, 2537–2549 (2024). https://doi.org/10.1007/s00170-023-11868-2

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