FEM-Based Simulation of Temperature in Speed Stroke Grinding with 3D Transient Moving Heat Sources

Abstract

The grinding process is one of the most important finishing processes to obtain high surface quality. Nowadays, grinding is also considered as a high performance process with high material removal rates. Nevertheless, to avoid thermally-induced structural changes poses a major challenge for this manufacturing technology. Until now, the Finite Element Method (FEM) has been widely applied as a proper numerical technique to predict workpiece properties in machining processes. However, actual models in grinding are limited to conventional grinding processes with simple workpiece profiles and low table speeds. In this paper, finite element simulations are expanded to 3-dimensional (3D) models with temperature-dependent material properties and heat source profiles derived from experimental results, i.e. tangential forces. Both temperature simulation and measurement were conducted for deep grinding, pendulum grinding and speed stroke grinding in the table speed range of vw = 12 m/min to 180 m/min and specific material removal rates of Q’w = 40 mm³/mms. Overall, the simulation results show a good agreement with the measured temperature and surface integrity after grinding. This research indicates that a 3D FE model with temperature dependent material properties can predict realistic temperature fields in speed stroke grinding. Therefore, the experiment and measurement costs and time can be reduced by FEM simulation.