Abstract
When grinding hard-to-machining materials such as titanium alloys, a massive grinding heat is generated and gathers in the grinding zone due to the low thermal conduction of the materials. The accumulated grinding heat easily leads to severe thermal damages to both the workpiece and the grinding wheel. A novel oscillating heat pipe (OHP) grinding wheel is one of the solutions to this phenomenon. The oscillating heat pipe grinding wheel can transfer the grinding heat directly from the grinding zone to avoid heat accumulation and a high temperature rise. In this paper, the temperature field of the grinding Ti-6Al-4V alloy is investigated, via the oscillating heat pipe grinding wheel, by numerical analysis. The three-dimensional thermal conduction model is built accordingly, containing the grinding wheel, grinding zone and Ti-6Al-4V workpiece. Due to the enhanced heat transport capacity of the oscillating heat pipe grinding wheel, the highest temperature in the grinding zone and the temperature on the ground surface of the workpiece decrease dramatically. For example, under a grinding heat flux of 1 × 107 W/m2, when using the grinding wheel without OHP and with OHPs, the highest temperature in the grinding zone drops from 917 °C to 285 °C by 68.7%, and the ground surface temperature decreases from 823 °C to 244 °C by 71.2%. Moreover, the temperature distribution on the grinding wheel is more uniform with an increase of the number of oscillating heat pipes.
Highlights
Hard-to-machining materials, such as titanium alloys, superalloys and composites, etc., are widely used in turbomachinery components [1]
Under a grinding heat flux of 3 × 106 W/m2, the highest temperature caused by the grinding wheel with 6 oscillating heat pipe (OHP) is 99 ◦ C, while the temperature generated by the grinding wheel without OHP is 258 ◦ C, 2.6 times the temperature generated by the grinding wheel with 6 OHPs
When the grinding heat flux reaches 1 × 107 W/m2, the highest temperature caused by the grinding wheel with 6 OHPs is just 286 ◦ C; the temperature caused by the grinding wheel without OHP rises as high as 917 ◦ C, which can lead to severe thermal damages
Summary
Hard-to-machining materials, such as titanium alloys, superalloys and composites, etc., are widely used in turbomachinery components [1]. The machining cost indexes of titanium alloys and superalloys are as high as 5.1 and 3.4, while the machining cost index of aluminum alloys is only 0.4 [7] Given all these problems, many studies have been conducted on the grinding parameters, grinding wheel or cooling method perspectives. Internal coolant delivery systems [34,35] and the modification of nozzles [36,37] are introduced to increase the cooling effect Another method, continuous dressing, is applied to maintain the sharpness of the grinding wheel in order to avoid grinding burn-out [38,39]. A novel method is needed to enhance the heat transfer in the grinding zone, so that the massive grinding heat will avoid accumulating in the grinding zone and causing a high temperature and thermal damages. To investigate the temperature distribution on the grinding wheel and the workpiece, grinding titanium alloy by the OHP grinding wheel is modelled by three-dimensional simulation in this paper
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