The search for an economic domain of operation when grinding below the film boiling limit

Abstract

An investigation has been conducted to determine whether an economic domain of shallow-cut grinding exists below the film boiling temperature. It identifies the potential benefits of grinding below film boiling and provides preliminary theoretical evidence based on accepted thermal analyses in grinding and the results of previous research. The evidence shows that an economic domain in shallow-cut grinding could exist. The stock removal rate reported by one group of researchers [ Bull Jap. Soc. Precision Engng 17(2), 133 (1983)] [1] was only 1 mm 3 (mm s) −1, whereas 5–6 mm 3 (mm s) −1 is commonly accepted as an economic stock removal rate in shallow-cut grinding. The present thermal analysis indicates that the stock removal rates of 16 mm 3 (mm s) −1 might be possible with alumina wheels operating at conventional wheel speeds with very small depths of cut. Rates higher than 250 mm 3 (mm s) −1 might be possible when using CBN wheels and high wheel speeds.