Rayleigh heat flux distribution model investigation and workpiece temperature prediction in the cylindrical grinding

Abstract

The ability to accurately predict the grinding temperature has been demonstrated in improving machining quality and reducing the cost in precision engineering. This paper focused on a new grinding temperature measurement and heat flux model based on the Rayleigh distribution in contact area. In order to validate the proposed model, an embedded thermocouple method was adopted to measure the surface temperature through inserting the grindable thermocouple into the workpiece. A dynamometer using Kistler 9347C was designed for cylindrical grinding and the grinding force was monitored. Based on the monitored temperature curves, the heat flux was calculated with the inverse heat transfer method and the real contact length was calculated. The results indicated that the heat source along the contact area is asymmetric and more consistent with Rayleigh curve by comparing to the quadratic curve heat source model. The energy partitions to the workpiece were obtained by analyzing the experimental grinding temperature and grinding force. With the real contact length model and energy partition model base on the experiments results, the predictive model for workpiece surface temperature and the heat flux was validated and showed very good agreement with the experimental results in cylindrical plunge grinding.