Modeling and simulation of temperature field in high-shear and low-pressure grinding with liquid-body-armor-like grinding wheel

Abstract

High-shear and low-pressure grinding using liquid-body-armor-like grinding wheel is a new grinding process. It has a great potential in the field of precision and ultra-precision machining. To clarify the unclear grinding heat characteristics, heat generation mechanism, and heat source distribution of the liquid-body-armor-like grinding wheel, a temperature field model was developed for high-shear and low-pressure grinding with ABAQUS. The thermal characteristics of the new grinding wheel were investigated by studying the heat flux and convective loads under different grinding parameters. The effectiveness of the heat model was validated through high-shear and low-pressure grinding experiments. The simulation results closely matched with the experimental results, with an average error of 5.84 % and a minimum error of 0.94 %. The grinding temperature decreased gradually from the centre of the heat source towards the edge of the workpiece in both horizontal and vertical directions. The temperature raised with the increase of the grinding velocity, ranging from 39.66 °C at 4 m/s to 77.82 °C at 14 m/s. It decreased with the workpiece feed rate, dropping from 39.66 °C at 500 mm/min to 32.00 °C at 3000 mm/min. As the normal grinding force increased, it gradually increases from 30.80 °C to 39.66 °C. The grinding temperature of the liquid-body-armor-like grinding wheel was lower than that of the traditional grinding wheel.