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Analytical Modelling of Temperature in Cylindrical Grinding to Predict Grinding Burns

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Abstract

The direct measurement of grinding temperature is always difficult due to coolant cover and very size of work and wheel interaction zone. At the same time, high heat generation in grinding often leads to grinding burns thereby affecting surface integrity; in this context, theoretical evaluation of temperature could facilitate early detection of the grinding burns. This paper therefore presents an analytical model to evaluate grinding temperature and correlates it with the occurrence of grinding burns in terms of BNA. In general, the analytical approach involves evaluating real contact length, grinding forces and finally grinding zone temperature for the plunge cylindrical grinding. The maximum rise in grinding temperature at the surface was calculated, for the wet grinding process by considering the total heat flux entering into the grinding system. Model validation experiments have been performed to measure BNA and identify parametric conditions that produce grinding burns. The model estimate of grinding zone temperature of 631 °C is in good agreement (92%) with other research works. Further, when the calculated grinding temperature reaches beyond 631 °C, the grinding burns are observed on the work surface with a BNA value of the order of 100 mp for the micro alloyed steel. The minimum thermal damage in terms of BNA is observed at higher levels of wheel speed and spark-out time and lower levels of depth of cut.

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Abbreviations

D :

Spherical grain diameter

C d :

Number of active grains per unit area

C w :

Specific heat density of work material

E 1 :

Modulus of elasticity of work-piece

E 2 :

Modulus of elasticity of grinding wheel

E*:

Elastic properties of work-wheel

F :

Friction coefficient between chip, grain, and the work-piece

F n :

Normal grinding force

\(F_{n}^{\prime }\) :

Specific normal grinding force

\(F_{nchip}^{\prime }\) :

Specific normal cutting force

\(F_{nslide}^{\prime }\) :

Specific normal sliding force

\(F_{nplough}^{\prime }\) :

Specific normal ploughing force

HB:

Brinell hardness number of the work-piece

L :

Paclet number

M :

Size of an abrasive grain mesh size

R a :

Surface roughness

R L :

Contact length ratio

R r :

Roughness factor

R ws :

Work-wheel fraction

T ch :

Chip temperature

V s :

Wheel velocity

V w :

Work velocity

a e :

Depth of cut

b :

Impression diameter

b w :

Width of grinding

d g :

Equivalent diameter of abrasive grain

d e :

Equivalent diameter of grinding wheel

d f :

Dynamic factor

d s :

Diameter of grinding wheel

d w :

Diameter of work-piece

f a :

Fraction of abrasive grain that actively cut in grinding

h :

Average un-deformed chip thickness

h f :

Fluid convection factor

k w :

Thermal conductivity

l c :

Real contact length

l fr :

Rough length of contact due to deflection

l fs :

Smooth length of contact due to deflection

l g :

Geometric length of contact

n w :

Work-piece speed

q ch :

Specific chip heat flux

q f :

Specific coolant heat flux

q t :

Total heat flux

v r :

In-feed

v 1 :

Poisson’s ratio of workpiece

v 2 :

Poisson’s ratio of grinding wheel

α :

Thermal diffusivity

β w :

Material thermal property

ρ w :

Density of work material

θ m :

Maximum rise in surface temperature

ε :

Fraction of energy entering into the work surface

δ :

Deflection due to normal grinding force

Ø :

Approach angle

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Authors and Affiliations

  1. Kalyani Centre for Technology and Innovation, Bharat Forge Ltd., Pune, India

    Azhar Thanedar

  2. Department of Industrial and Production Engineering, Vishwakarma Institute of Technology, Pune, India

    Ganesh G. Dongre

  3. Department of Mechanical Engineering, Indian Institute of Technology Bombay, Powai, Mumbai, 400076, India

    Suhas S. Joshi

Authors
  1. Azhar Thanedar
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  2. Ganesh G. Dongre
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  3. Suhas S. Joshi
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Correspondence to Suhas S. Joshi.

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Thanedar, A., Dongre, G.G. & Joshi, S.S. Analytical Modelling of Temperature in Cylindrical Grinding to Predict Grinding Burns. Int. J. Precis. Eng. Manuf. 20, 13–25 (2019). https://doi.org/10.1007/s12541-019-00037-9

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  • DOI: https://doi.org/10.1007/s12541-019-00037-9

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