Analysis of the material removal and heat transfer during internal cooling grinding of GH4169

Abstract

Nickel-based superalloys exhibit exceptional characteristics and have extensive applications in marine, energy, chemical, and various other fields. Nevertheless, nickel-based superalloys tend to produce substantial heat while being ground. The air barrier effect makes it difficult to spray coolant onto the grinding surface, resulting in poor cooling that leads to surface quality deterioration. This paper proposes a pressurized internal cooling grinding wheel with a removable abrasive ring to investigate the effects of flow channel structure and abrasive ring mounting position on grinding performance. A model was constructed to assess the flow and temperature fields of the grinding arc area, utilizing flow-solid heat transfer. The simulation results indicated that the cooling effect was more effective when the flow channel structure was a 2 mm diameter arc and the runner outlet was placed in the gap area. Additional trials were carried out on the grinding of GH4169 superalloys using pressurized internal cooling wheels to assess and evaluate the impact of flow channel structure and runner outlet position on grinding temperature, surface roughness, and surface topography. The findings indicate that the grinding wheel, characterized by its arc-shaped flow channel structure and runner outlet position within the gap area, exhibits superior grinding performance, resulting in reduced grinding temperature and enhanced surface quality.