Numerical analysis of coolant flow in the grinding zone

Stachurski, Wojciech; Sawicki, J.; Krupanek, Krzysztof; Nadolny, Krzysztof

doi:10.1007/s00170-019-03966-x

Cited by 20 publications

(2 citation statements)

References 29 publications

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“…The research method over computational fluid dynamics for solid-liquid two-phase fluids allows numerical modelling of some difficult-to-observe quantities. The results obtained by this method are highly consistent with the actual results and have perfect repeatability [11][12][13]. Relevant work have been conducted by different researchers.…”

Section: The Transient Variability Of the Abrasive Particles Trajecto...supporting

confidence: 83%

Modeling of solid–liquid coupling and material removal in robotic wet polishing

Pan

Chen

Jin

et al. 2023

Int J Adv Manuf Technol

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In this paper, the flow characteristics of the polishing fluid between the polishing pad and the workpiece are studied for the robotic wet polishing process, and the distribution of the polishing fluid radial velocity Ur and the liquid film thickness z at different rotating radii r are revealed. The two-dimensional computational domain consisting of the polishing pad surface, the workpiece wall and the polishing fluid is established. The particle-liquid two-phase flow simulation is carried out in Fluent, and the influence of different rotation rate ω of the polishing pad and different robot swing speeds v2 on the change and distribution of polishing fluid flow rate and temperature are elaborated. The position distribution of the abrasive particles in the wet polishing process and the velocity distribution of particles in the x and y directions impacting on the workpiece surface are simulated and analyzed for polishing fluids with different average abrasive diameters dp. The three-dimensional calculation domain for wet polishing is established; the workpiece surface erosion is simulated in Fluent; the material removal rate MRR and standard deviation of material removal σ on the workpiece surface are calculated considering different combinations of polishing fluid properties Ci and polishing kinematics Pi. Under the same process parameters, the material removal rate test value MRRT and the standard deviation of material removal test value σT are compared with the simulated values, respectively. The results show that under the combination of 64 groups of physical parameters C1-C64 of the polishing fluid, the error between the test value MRRT, σT and the simulationvalue MRR, σ is within 5%. With 64 sets of polishing kinematics parameters P1-P64, the average error between the test value MRRT and the simulated value MRR is 4.19%. However, when the polishing pad rotation rate ω is high, there is an inefficient polishing area in the smaller radius from the polishing pad rotation center, which results in a lower MRRT in some tests than that in simulation, with an maximum error of 8.1%. The average error between the test value σT and the simulation value σ is 3.77%. When the pressure P of the polishing pad is high, the large particles embedded in the polishing pad surface follow its rotation, causing deep scratches on the workpiece surface, which results in a larger σT in some tests, with an maximum error of 7.8%. In conclusion, the material removal principle and the influence of different process parameters in the robotic wet polishing process are revealed in this paper.through modeling and simulation of the particle-liquid two-phase flow, giving an accurate estimation of the material removal rate of the robotic wet polishing process.

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Section: The Transient Variability Of the Abrasive Particles Trajecto...supporting

confidence: 83%

Modeling of solid–liquid coupling and material removal in robotic wet polishing

Pan

Chen

Jin

et al. 2023

Int J Adv Manuf Technol

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“…Grinding is an essential manufacturing process to produce metallic parts, in which a metalworking fluid (MWF) jet is used for lubrication and cooling of the grinding zone to prevent part damage by grinding burn [1]. Several empirical experiments and simulations to characterize the cooling performance were carried out so far, whereby only an indirect optimisation of the MWF jet flow was performed [2][3][4][5][6]. Since the cooling performance is directly related to the fluid flow, in-depth knowledge of the flow field is essential for understanding the heat transfer associated with the grinding process [7,8].…”

Section: Introduction 1motivationmentioning

confidence: 99%

Feasibility of Optical Flow Field Measurements of the Coolant in a Grinding Machine

et al. 2021

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For industrial grinding processes, the workpiece cooling by metalworking fluids, which strongly influences the workpiece surface layer quality, is not yet fully understood. This leads to high efforts for the empirical determination of suitable cooling parameters, increasing the part manufacturing costs. To close the knowledge gap, a measurement method for the metalworking fluid flow field near the grinding wheel is desired. However, the varying curved surfaces of the liquid phase result in unpredictable light deflections and reflections, which impede optical flow measurements. In order to investigate the yet unknown optical measurement capabilities achievable under these conditions, shadowgraphy in combination with a pattern correlation technique and particle image velocimetry (PIV) are applied in a grinding machine. The results show that particle image velocimetry enables flow field measurements inside the laminar metalworking fluid jet, whereby the shadowgraph imaging velocimetry complements these measurements since it is in particular suitable for regions with spray-like flow regimes. As a conclusion, optical flow field measurements of the metalworking fluid flow in a running grinding machine are shown to be feasible.

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