Abstract
Tensile stress and thermal damage resulting from thermal loading will reduce the anti-fraying and anti-fatigue of workpieces, which is undesirable for micro-grinding, so it is imperative to control the rise of temperature. This investigation aims to propose a physical-based model to predict the temperature with the process parameters, wheel properties and material microstructure taken into account. In the calculation of heat generated in the micro-grinding zone, the triangular heat-flux distribution is adopted. The reported energy partition model is also utilized to calculate the heat converted into the workpiece. In addition, the Taylor factor model is used to estimate the effects of crystallographic orientation (CO) and its orientation distribution function (ODF) on the workpiece temperature by affecting the flow stress and grinding forces in micro-grinding. Finally, the physical model is verified by performing micro-grinding experiments using the orthogonal method. The result proves that the prediction matches well with the experimental values. Besides, the single-factorial experiments are conducted with the result showing that the model with the consideration of the variation of Taylor factor improves the accuracy of the temperature prediction.
Highlights
Aluminum alloy AA7075 (Al À Zn À Mg À Cu) is an ideal material for the aerospace industries because of the high strength and light-weight [1] and its utilization in aircraft is extensive [2]
In the calculation of grinding power, the mechanical load was modeled by considering the process parameters, the workpiece material microstructure, and the micro-grinding wheel topography
This paper predicted the effect of texture on micro-grinding temperature on the basis of the developed Taylor factor model which quantifies the effects of the crystallographic orientation (CO) and the orientation distribution function (ODF) on the flow stress
Summary
Aluminum alloy AA7075 (Al À Zn À Mg À Cu) is an ideal material for the aerospace industries because of the high strength and light-weight [1] and its utilization in aircraft is extensive [2]. The calculation of the workpiece temperature consists of modeling the heat flux distribution and the energy partition. Some techniques have been proposed to calculate the energy partition, including calorimetric method and inverse heat transfer method. Rowe et al [11,12,13] proposed calorimetric method to obtain the heat partition entering workpiece and theoretically model the temperature. Gou and Milkin [14,15] developed three inverse heat transfer methods, including temperature matching, integral, and.
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