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Research on temperature field of non-uniform heat source model in surface grinding by cup wheel

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Abstract

To address the problems of thermal damage to a workpiece surface caused by the instantaneous high temperature during grinding and the difficulty in monitoring temperature in real time, the temperature field in the case of composite surface grinding by a cup wheel is studied. In order to predict the grinding temperature, considering material removal and grinding force distribution, a non-uniform heat source model with different function distributions in the circumferential and radial directions in the cylindrical coordinate system is first proposed; then, the analytical model is deduced and the numerical model of the temperature field is established based on the heat source model. The validation experiments for grinding temperature field are carried out using a high-definition infrared thermal imager and an artificial thermocouple. Compared to the temperature field based on the uniform heat source model, the results based on the non-uniform heat source model are in better agreement with the actual temperature field, and the temperature prediction error is reduced from approximately 23% to 6%. Thus, the present study provides a more accurate theoretical basis for preventing burns in cup wheel surface grinding.

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Abbreviations

\(\zeta\) :

Energy partition

\(q_{x}\) :

Heat flux

\(F_{\text{n}}\) :

Normal grinding force (N)

\(F_{\text{t}}\) :

Tangential grinding force (N)

\(F_{\text{f}}\) :

Friction force (N)

\(F_{\text{c}}\) :

Cutting and ploughing force (N)

\(v_{\text{c}}\) :

Composite speed (m/s)

\(v_{\text{s}}\) :

Wheel speed (m/s)

\(v_{\text{w}}\) :

Feel velocity (m/s)

\(l_{\text{c}}\) :

Length of contact arc

\(b_{\text{s}}\) :

Width of parallel wheel

\(a_{\text{p}}\) :

Grinding depth

\(a_{\text{s}}\) :

Distance between two adjacent abrasive grains

\(q_{{\text{cutting}}}\), \(q_{{\text{friction}}}\) :

Instantaneous heat fluxes generated by \(F_{\text{c}}\) and \(F_{\text{f}}\) (W)

\(R_{\text{w}}\) :

Heat partition ratio between the workpiece and grinding wheel

\(k_{\text{w}}\), \(k_{{\text{g} }}\) :

Thermal conductivities of the workpiece and grinding wheel

\(V_{\text{f}}\) :

Volume fraction of fibers

\(V_{\text{d}}\) :

Volume fraction of the abrasive

\(\lambda {}_{\text{f}},\lambda {}_{\text{m}}\) :

Thermal conductivities of fiber and epoxy resin

\(\lambda {}_{\text{r}},\lambda {}_{\text{d}}\) :

Thermal conductivity of the resin bind to that of the abrasive

\(h_{\text{m}}\) :

Distance of the wheel movement

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Acknowledgements

This work was supported by the Natural Science Foundation of Hebei Province (Grant No. F2017202243), the Natural Science Foundation of Tianjin (Grant No. 18JCTPJC54700), the State Key Laboratory of Robotics and System (HIT) (Grant No. SKLRS-2017-KF-15), and the Science and Technology on Space Intelligent Control Laboratory (Grant No. ZDSYS-2017-08).

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Authors and Affiliations

  1. State Key Laboratory of Reliability and Intelligence of Electrical Equipment, Hebei University of Technology, Tianjin, 300130, People’s Republic of China

    Shi-Jie Dai, Xiao-Qiang Li & Hui-Bo Zhang

  2. School of Mechanical Engineering, Hebei University of Technology, Tianjin, 300130, People’s Republic of China

    Shi-Jie Dai, Xiao-Qiang Li & Hui-Bo Zhang

  3. Hebei Key Laboratory of Robot Perception and Human-Robot Interaction, Tianjin, 300130, People’s Republic of China

    Shi-Jie Dai, Xiao-Qiang Li & Hui-Bo Zhang

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  1. Shi-Jie Dai
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  2. Xiao-Qiang Li
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Correspondence to Hui-Bo Zhang.

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Dai, SJ., Li, XQ. & Zhang, HB. Research on temperature field of non-uniform heat source model in surface grinding by cup wheel. Adv. Manuf. 7, 326–342 (2019). https://doi.org/10.1007/s40436-019-00272-3

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  • DOI: https://doi.org/10.1007/s40436-019-00272-3

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