Skip to main content
SpringerLink
Log in

Epitrochoid heat flux distribution model for cylindrical grinding considering influence of process parameter

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

Abstract

The main disadvantage caused by the traditional heat sources is due to the lack of adaptability to the change of process parameters, resulting in a larger calculation error in the calculation of grinding temperature. For this, an epitrochoid heat flux distribution (EHFD) model for cylindrical grinding considering the influence of process parameters is established. In doing so, the grinding trajectory of two adjacent grains that can vary adaptively with the process parameters is employed to determine the equation of epitrochoid heat flux curve, and the grinding temperature is further obtained by the moving heat source theory. After the validation of the grinding temperature experiment and comparisons with the traditional heat sources, the superiority of the proposed method is reflected in grinding trajectory, undeformed chip thickness, heat source shape, and grinding temperature at the varied process parameters. The change in process parameters can make the epitrochoid heat flux distribution exhibit the widely used triangular heat source characteristic at its leading edge, causing the newly proposed heat source to have a better temperature prediction ability than other heat source models.

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
Fig. 18

Similar content being viewed by others

Data availability

All data supporting the findings of this study are included in this article.

Code availability

The method codes involved in this paper are not applicable.

Abbreviations

a gmax :

Maximum undeformed chip thickness (mm)

a p :

Grinding depth (μm)

b w, b s :

Widths of workpiece and wheel (m)

c f , c g , c w :

Specific heat capacities of grinding fluid, abrasive grain and workpiece (J/(kg·K))

E s, E w :

Young’s moduli of wheel and workpiece (GPa)

f a(x), f b(x):

Trajectory equations of the grains a and b

F(x):

Equation of the epitrochoid heat source curve

F max, F min :

Maximum and minimum values of epitrochoid heat source curve

F n, F t :

Normal and tangential grinding forces (N)

h f, h w :

Convection heat transfer coefficients of grinding fluid and workpiece (W/(m2·K))

k f, k g, k w :

Thermal conductivities of grinding fluid, abrasive grain and workpiece (W/(m·K))

l c :

Real contact arc length (mm)

N d :

Active grits number per unit area

O 1-xy :

Global coordinate system

O 1-rθ :

Polar coordinate system

q(ξ):

Heat flux into workpiece (W/m2)

q t :

Total grinding heat flux (W/m2)

r 0 :

Effective contact radius of grain (mm)

r s, r w :

Radii of wheel and workpiece (m)

R r :

Roughness factor of wheel

R w :

Energy partition of workpiece

R wch , R ws :

Workpiece-chip partition ratio and workpiece-wheel partition ratio

t :

Single grinding time

T :

Grinding temperature (℃)

v s, v w :

Speeds of grinding wheel and workpiece (m/s)

ω s, ω w :

Angular velocities of grinding wheel and workpiece (rad/s)

x a, y a :

Trajectory equations of the grains a

x b, y b :

Trajectory equations of the grains b

α w, α g :

Thermal diffusivities of workpiece and abrasive grain (m2/s)

β w :

Thermal property parameter for workpiece (m2/s)

υ s , υ w :

Poisson’s ratios of wheel and workpiece

θ a, θ b :

Polar angle of grains a and b (°)

θ c :

Half of grit tip angle (°)

φ c :

Shear angle (°)

γ c :

Shear strain

\({\rho }_{f}\) :

Density of grinding fluid (kg/m3)

\({\eta }_{f}\) :

Viscosity of grinding fluid (Pa·s)

References

  1. Malkin S, Guo C (2007) Thermal analysis of grinding. CIRP Ann 56(2):760–782

    Article  Google Scholar 

  2. Thanedar A, Dongre GG, Joshi SS (2019) Analytical modelling of temperature in cylindrical grinding to predict grinding burns. Int J Precis Eng Man 20:13–25

    Article  Google Scholar 

  3. Jaeger JC (1942) Moving sources of heat and the temperature at sliding contacts. J Proc Roy Soc NSW 76:203–204

    Google Scholar 

  4. Wang L, Qin Y, Liu ZC, Ge PQ, Gao W (2003) Computer simulation of a workpiece temperature field during the grinding process. P I Mech Eng B-J Eng 217(7):953–959

    Google Scholar 

  5. Desruisseauk NR, Zerkle RD (1970) Thermal analysis of grinding progress. J Eng Ind 92(2):428–433

    Article  Google Scholar 

  6. Malkin S, Anderson RB (1974) Thermal aspects of grinding, part 1-energy partition. J Eng Ind 96:1177–1183

    Article  Google Scholar 

  7. Tian Y, Shirinzadeh B, Zhang D, Liu X, Chetwynd D (2009) Effects of the heat source profiles on the thermal distribution for ultraprecision grinding. Precis Eng 33:447–458

    Article  Google Scholar 

  8. Kohli S, Guo C, Malkin S (1995) Energy partition to the workpiece for grinding with aluminum oxide and CBN abrasive wheels. J Eng Ind 5(117):161–168

    Google Scholar 

  9. Kim NK, Guo C, Malkin C (1997) Heat flux distribution and energy partition in creep-feed grinding. CIRP Ann-Manuf Techn 46(1):227–232

    Article  Google Scholar 

  10. Rowe WB, Black SCE, Mills B, Qi HS, Morgan MN (1995) Experimental investigation of heat transfer in grinding. CIRP Ann-Manuf Techn 44(1):329–332

    Article  Google Scholar 

  11. Zheng Y, Wang CQ, Zhang YF, Meng FM (2022) Study on temperature of cylindrical wet grinding considering lubrication effect of grinding fluid. Int J Adv Manuf Tech 121:6095–6109

    Article  Google Scholar 

  12. Jin T, Rowe WB, McCormack D (2002) Temperatures in deep grinding of finite workpieces. Int J Mach Tool Manu 42:53–59

    Article  Google Scholar 

  13. Pang JZ, Wu CJ, Shen YM, Liu SQ, Wang QX, Li BZ (2019) Heat flux distribution and temperature prediction model for dry and wet cylindrical plunge grinding. P I Mech Eng B-J Eng 233(10):2047–2060

    Google Scholar 

  14. Guo C, Malkin S (1996) Inverse heat transfer analysis of grinding, part 1: methods. J Eng Ind 118(2):137–142

    Article  Google Scholar 

  15. Guo C, Malkin S (1996) Inverse heat transfer analysis of grinding, part 2: applications. J Eng Ind 118(2):143–149

    Article  Google Scholar 

  16. Jin T, Stephenson DJ (2006) Heat flux distributions and convective heat transfer in deep grinding. Int J Mach Tool Manu 46(14):1862–1868

    Article  Google Scholar 

  17. Brosse A, Naisson P, Hamdi H, Bergheau JM (2008) Temperature measurement and heat flux characterization in grinding using thermography. J Mater Process Tech 201(1):590–595

    Article  Google Scholar 

  18. Wang DX, Sun SF, Jiang JL, Liu XF (2017) The profile analysis and selection guide for the heat source on the finished surface in grinding. J Manuf Process 30:178–186

    Article  Google Scholar 

  19. Li BZ, Zhu DH, Pang JZ, Yang JG (2011) Quadratic curve heat flux distributionmodel in the grinding zone. Int J Adv Manuf Tech 54:931–940

    Article  Google Scholar 

  20. Jiang JL, Ge PQ, Sun SF, Wang DX, Wang YL, Yang Y (2016) From the microscopic interaction mechanism to the grinding temperature field: an integrated modelling on the grinding process. Int J Mach Tool Manu 110:27–42

    Article  Google Scholar 

  21. Rowe WB, Morgan MN, Qi HS, Zheng HW (1993) The effect of deformation on the contact area in grinding. CIRP Ann 42:409–412

    Article  Google Scholar 

  22. Jin T, Stephenson DJ, Rowe WB (2003) Estimation of the convection heat transfer coefficient of coolant within the grinding zone. P I Mech Eng B-J Eng 217:397–407

    Google Scholar 

  23. Rowe WB, Black SCE, Mills B, Qi SH (1996) Analysis of grinding temperatures by energy partitioning. P I Mech Eng B-J Eng 210:579–588

    Google Scholar 

  24. Zhang L, Rowe WB (2020) Study of convective heat transfer in grinding applied to tool carbide. J Manuf Sci E-T ASME 142:1–30

    Article  Google Scholar 

  25. Zhang L, Rowe WB, Morgan MN (2013) An improved fluid convection solution in conventional grinding. P I Mech Eng B-J Eng 227:832–838

    Google Scholar 

  26. Li GF, Wang LS (2001) Simulation and optimum for plunge grinding. Key Eng Mater 202–203:219–226

    Article  Google Scholar 

  27. Rowe WB (2009) Principles of modern grinding technology. William Andrew Publishing, USA

    Google Scholar 

Download references

Funding

This work was supported by the National Natural Science Foundation of China (No.52175160) and the Science and Technology Research Program of Chongqing Municipal Education Commission (Grant No.KJQN202301347).

Author information

Authors and Affiliations

  1. The State Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing, 400044, China

    Changqing Wang, Yong Zheng, Jiang Long, Yifei Zhang & Fanming Meng

  2. Harbin Dong’an Engine Co., Ltd, Harbin, China

    Changqing Wang

  3. School of Intelligent Manufacturing Engineering, Chongqing University of Arts and Sciences, Chongqing, 402160, China

    Yong Zheng

  4. College of Aerospace Engineering, Chongqing University, Chongqing, 400044, China

    Yong Zheng

Authors
  1. Changqing Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yong Zheng
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jiang Long
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yifei Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Fanming Meng
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

CW: investigation, methodology, software, writing—review and editing. YZ: investigation, software, data curation, writing—original draft. JL: validation, data curation. YZ: investigation, formal analysis, visualization. FM: conceptualization, funding acquisition, project administration, supervision, writing—review and editing.

Corresponding author

Correspondence to Fanming Meng.

Ethics declarations

Ethics approval

The authors declare that this manuscript was not submitted to more than one journal for simultaneous consideration. The submitted work is original and has not been published elsewhere in any form or language.

Consent to participate and publish

The authors declare that they consent to participate in and publish this paper.

Conflict of interest

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

Wang, C., Zheng, Y., Long, J. et al. Epitrochoid heat flux distribution model for cylindrical grinding considering influence of process parameter. Int J Adv Manuf Technol 129, 4829–4844 (2023). https://doi.org/10.1007/s00170-023-12564-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-12564-x

Keywords

Search

Navigation