Development of a simple technique for improving the efficacy of fluid flow through the grinding zone

Abstract

Grinding is inherently characterized by very high-localized heating. Usually, the high grinding zone temperature is controlled by copious supply of cutting fluid. But, in reality, such cooling is not as effective as expected. The efficiency of flood cooling is very small as the coolant is obstructed from coming into actual contact with the wheel and entering into the grinding zone due to the formation of thin but stiff peripheral air boundary layer on the grinding wheel rotating at high speed in otherwise static ambient air. The increase of flow rate of coolant through the grinding zone, therefore, has become extremely essential. In the present development work, a nozzle has been designed that helps break the air layer before it reaches grinding zone, prevent air suction from the sides and at the same time force the adequate fluid towards the grinding zone. Performance of this nozzle is evaluated by separating, collecting and measuring fluid flow actually passing through the grinding zone for different nozzle locations and orientations. An attachment is designed to maneuver the nozzle for the purpose. A special work-piece-cum-fluid collecting chute is designed to measure the effective flow rate. The effective flow rate of the coolant, thus obtained, is then compared with that measured with flood cooling system originally available with the grinding machine. The developed nozzle system is found to be quite effective in enhancing the actual coolant flow through the grinding zone.