Abstract
For industrial grinding processes, the workpiece cooling by metalworking fluids, which strongly influences the workpiece surface layer quality, is not yet fully understood. This leads to high efforts for the empirical determination of suitable cooling parameters, increasing the part manufacturing costs. To close the knowledge gap, a measurement method for the metalworking fluid flow field near the grinding wheel is desired. However, the varying curved surfaces of the liquid phase result in unpredictable light deflections and reflections, which impede optical flow measurements. In order to investigate the yet unknown optical measurement capabilities achievable under these conditions, shadowgraphy in combination with a pattern correlation technique and particle image velocimetry (PIV) are applied in a grinding machine. The results show that particle image velocimetry enables flow field measurements inside the laminar metalworking fluid jet, whereby the shadowgraph imaging velocimetry complements these measurements since it is in particular suitable for regions with spray-like flow regimes. As a conclusion, optical flow field measurements of the metalworking fluid flow in a running grinding machine are shown to be feasible.
Highlights
Since the cooling performance is directly related to the fluid flow, in-depth knowledge of the flow field is essential for understanding the heat transfer associated with the grinding process [7,8]
The feasibility of optical measurements of the metalworking fluid (MWF) flow in a grinding process is investigated for a simplified setup without workpiece
The majority of the presented flow field measurements is based on characteristic flow structures, which are visualised with shadowgraphy and used as flow tracers for shadowgram image velocimetry (SIV)
Summary
Grinding is an essential manufacturing process to produce metallic parts, in which a metalworking fluid (MWF) jet is used for lubrication and cooling of the grinding zone to prevent part damage by grinding burn [1]. Since the cooling performance is directly related to the fluid flow, in-depth knowledge of the flow field is essential for understanding the heat transfer associated with the grinding process [7,8]. A flow velocity field measurement of the MWF flow in a grinding machine has not been performed so far, either with or without workpiece. The fluid concentration in the regions with MWF-air mixtures (spray) strongly influences the cooling performance, but this effect is beyond the scope of the presented investigations
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