A study of dynamic energy partition in belt grinding based on grinding effects and temperature dependent mechanical properties

Abstract

• A dynamic energy partition calculating model in abrasive belt grinding is proposed. • Cutting and ploughing dominate material removal for soft material while ploughing is more dominant for hard material. • Heat accumulation of grains reduces cooling capacity of abrasive belt during grinding. • High grinding temperature softens workpiece and makes cutting action occur easily. Analyzing and modelling the dynamic energy partition is of great significance to revealing the mechanism of belt grinding and improving grinding quality. However, there is lack of comprehensive studies on energy partition in belt grinding, especially when the dynamic characteristics are under consideration. To fill this gap, this paper analyzed the grinding energy partition from the perspective of grinding effects and thermal aspects. Grinding effects are distinguished by combination of single grain scratch tests and force balance of one grain in view of dynamic and elastic contact conditions. Thermal aspects are obtained by a fusion method of finite element method (FEM) and optimization algorithm. Then, by utilizing the iterative approach, heat accumulating effect and temperature dependent mechanical properties of workpieces are taken into account either and the dynamic energy partition is calculated in a continuous grinding process. Validations on two workpieces (made by SUS304 and AA6061-T6) prove that the proposed dynamic energy partition calculating method is effective and the maximum error of q w is 17.2 %. The proposed method not only enhances the understanding of dynamic energy partition in robotic belt grinding, but also offers a new venue for studying abrasive belt grinding.