Comparison of numerically and analytically predicted contact temperatures in shallow and deep dry grinding with infrared measurements

Abstract

Contact zone thermal models of the grinding process are an important tool for the proper selection of process parameters to minimize workpiece damage while improving process efficiency. Validating contact zone thermal models with experimental measurements is difficult due to the high-speed and stochastic nature of the grinding process. In this work an infrared imaging system is used to validate two numerical thermal models, which are then compared to an established analytical contact zone thermal model. The two numerical thermal models consist of a shallow grinding model and a deep grinding model, where the deep grinding model takes the contact angle into account while the shallow grinding model does not. The results show that at small depths of cut both the numerical models and the analytical model perform well; however, as the depth of cut is increased the numerical models’ accuracy increases as compared to the analytical model. The increase in accuracy may be a result of the 2D solution of the numerical models as compared to the 1D solution of the analytical model. Additionally, it was found that the contact angle has very little effect on the contact temperatures. This work also reinforces Rowe's analytical work, using experimental and numerical results, which indicated that the workpiece temperatures are reduced by grinding at higher Peclet numbers for a given material removal rate.