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Research and process optimization of crankshaft grinding parameters based on Gaussian heat source model

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Abstract

In the grinding process of crankshafts, the grinding parameters were improperly selected, which easily caused the high temperature in the grinding zone and led to burns on the crankshaft journal surface. To address this issue, referencing previous studies, the suitability of the Gaussian heat source model was verified by comparing it with three different heat source models. The Gaussian heat source model was applied to predict the temperature on the surface of the crankshaft connecting rod journal. Transient thermal analysis and investigation of material phase transformation were employed to explore the mechanism of grinding burns. The interaction effects among grinding parameters were analyzed using the Box-Behnken design, and a multiple linear regression equation was established for response surface optimization. The results demonstrated that applying the Gaussian heat source model and response surface optimization yielded the optimal solution, with a maximum deviation of 1.37% between the simulation and optimization results. By selecting a grinding depth (ap) of 0.40 mm, wheel speed (vs) of 40.00 m/s, and feed rate (vx) of 0.036 mm/s as the processing parameters, the temperature in the grinding zone was reduced to 659.37 °C, effectively mitigating grinding burns.

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Funding

The study supported this work on the Influence of J08E Crankshaft Technology and Structure Design on Crankshaft strength (Grant No. CD22111X).

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Author notes

  1. Le Li, Yanping Wang, Bin Huang and Kunming Liu contributed equally to this work.

Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Guilin University of Electronic Technology, 541004, Guangxi, China

    Siyuan Wang, Qiuyun Mo, Le Li & Yanping Wang

  2. Guangxi Key Laboratory of Manufacturing System and Advanced Manufacturing Technology, 541004, Guangxi, China

    Qiuyun Mo

  3. Guilin Fuda Co., Ltd., 541004, Guangxi, China

    Bin Huang & Kunming Liu

Authors
  1. Siyuan Wang
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  2. Qiuyun Mo
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  3. Le Li
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  4. Yanping Wang
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  5. Bin Huang
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  6. Kunming Liu
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Contributions

All authors contributed to the idea and design of this study. The initial idea of this paper was provided by Qiuyun Mo. The data collection, model building, and parameter optimization was done by Siyuan Wang. The first draft of the manuscript was written by Siyuan Wang. All authors revised the first few versions of the manuscript, read and approved the final manuscript carefully.

Corresponding author

Correspondence to Qiuyun Mo.

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Wang, S., Mo, Q., Li, L. et al. Research and process optimization of crankshaft grinding parameters based on Gaussian heat source model. Int J Adv Manuf Technol 132, 601–611 (2024). https://doi.org/10.1007/s00170-024-13331-2

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  • DOI: https://doi.org/10.1007/s00170-024-13331-2

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