The use of computational fluid dynamics in the analysis of fluid flow and thermal aspects in grinding

Mihić, Stefan; Dražumerič, Radovan; Pušavec, Franci; Badger, Jeffrey; Krajnik, Peter

doi:10.1177/0954405415624657

Cited by 9 publications

(4 citation statements)

References 24 publications

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“…For the used grinding parameters, the corresponding R w can be calculated by equation (11). The effect of grinding parameters and coolant changes on R w is shown in Figure 9.…”

Section: Methodsmentioning

confidence: 99%

“…The heat source of the front 1/2 arc in the grinding arc zone is reduced by cooling. Substituting the values of the heat flux in Figure 16(b), R w and k calculated by equations (11) and (22), into equation 8, the calculated workpiece surface temperature distribution can be obtained as in Figure 16(c). For dry grinding, the experimental maximum temperature is 263.4°C, while the calculated value is 260.0°C, which means that the predicted error is 1.3%.…”

Section: Experimental Temperatures and Heat Fluxmentioning

confidence: 99%

“…The useful fluid entering the grinding zone and crossing the interface would be decreased to 5%–40%. 10 Mihic et al 11 developed a numerical model based on computational fluid dynamics (CFD) to analyze fluid flow and thermal aspects in grinding and indicated that the useful flow rate is around 20%. Jin and colleagues 12,13 estimated of the convection heat transfer coefficient of coolant within the grinding zone and analyzed the grinding chip temperature and energy partitioning in high-efficiency deep grinding.…”

Section: Introductionmentioning

confidence: 99%

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Heat flux distribution and temperature prediction model for dry and wet cylindrical plunge grinding

Pang

Shen

et al. 2018

Proceedings of the Institution of Mechanical Engineers, Part B:

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The grinding heat is generally partitioned into the workpiece, wheel, chips and fluid in grinding process. The total amount of heat flux entering into the workpiece greatly affects the final workpiece surface temperature, which may cause undesirable workpiece burn. Moreover, the variable grinding chip thickness and fluid injection speed along the grinding contact zone could substantially change the specific energy and the shape of the heat source correspondingly. In this article, a Weibull heat flux distribution model for both dry and wet grinding temperature prediction was proposed by analyzing two key parameters: energy partition Rw and shape parameter k. The value of Rw was obtained by considering the real contact length, the active grits number and the average grit radius r0 on the basis of traditional formulas. The relationship between shape parameters k and useful flow was established by a FLUENT simulation of the convective grinding fluid applied in grinding contact zone with wheel-workpiece minimum clearance. The grinding temperature and grinding force experiments were conducted on a grinding machine MGKS1332/H to validate the proposed heat flux model. The calculated workpiece surface temperature distribution was obtained by using the experimental heat flux obtained by the reverse algorithm, and the error between calculated temperature and experimental temperature was analyzed. With the monitored force signals and the proposed temperature prediction model, the grinding temperature for both dry and wet grinding can be predicted, which will be helpful to the optimization and control of temperature in grinding process.

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“…For the used grinding parameters, the corresponding R w can be calculated by equation (11). The effect of grinding parameters and coolant changes on R w is shown in Figure 9.…”

Section: Methodsmentioning

confidence: 99%

Section: Experimental Temperatures and Heat Fluxmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Heat flux distribution and temperature prediction model for dry and wet cylindrical plunge grinding

Pang

Shen

et al. 2018

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…This may explain the fact that lower rounder errors were recorded after machining with conventional coolant flow when compared with the MQL technique, irrespective of the wheel cleaning jet. Mihic et al 31 carried out an analysis on thermal and fluid flow aspects in grinding using a two-dimensional (2D) numerical grinding model by CFD software (ANSYS). The results presented the fact that the useful flow rate is around 20%, since the application of the cutting fluid provides bulk cooling to the workpiece.…”

Section: Component Roundnessmentioning

confidence: 99%

Application of the auxiliary wheel cleaning jet in the plunge cylindrical grinding with Minimum Quantity Lubrication technique under various flow rates

Bianchi

Rodriguez

Hildebrandt

et al. 2018

Proceedings of the Institution of Mechanical Engineers, Part B:

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Minimum Quantity Lubrication is an alternative technique to conventional techniques that are related to environmental sustainability and economic benefits. This technique promotes the substantial reduction of the amount of coolant employed in machining processes, representing a mitigation of risks to people’s health that are involved with the process. On the other hand, it has been reported in the literature that some problems of using the Minimum Quantity Lubrication technique can impair the grinding efficiency. One of these problems is associated with wheel clogging phenomenon, which is caused by inefficient chip removal from the cutting zone as well as from mixture of metal dust and oil accumulated on the wheel surface during grinding. If chips lodge inside the pores of the grinding wheel as machining progresses, they will adversely affect dimensional and geometric quality of final product. Also, this will require more frequent dressing. A solution for this problem can be an effective cleaning system of the abrasive wheel during grinding with the traditional Minimum Quantity Lubrication technique Assisted with Wheel Cleaning Jet. In this context and aiming to explore the various potential health, environmental and economic benefits that have been widely reported in the literature about the use of Minimum Quantity Lubrication technique in grinding, this study presents an application of the Minimum Quantity Lubrication technique at flow rates (30, 60 and 120 mL/h) and assisted with wheel cleaning jet (Minimum Quantity Lubrication + Assisted with Wheel Cleaning Jet) in plunge grinding of a hardened steel with an aluminum oxide wheel. Experiments were also carried out with traditional Minimum Quantity Lubrication (without wheel cleaning) and with the conventional coolant techniques for comparison. The output variables were geometrical errors (surface roughness and roundness) of the workpiece, diametric wheel wear, acoustic emission, vibration and tangential cutting force. Results showed that Minimum Quantity Lubrication + Assisted with Wheel Cleaning Jet (with wheel cleaning jet) not only outperformed the traditional Minimum Quantity Lubrication technique in all the parameters analyzed, but in some cases it proved to be compatible with the conventional coolant technique under the conditions investigated. Also, most of values of the output parameters tested decreased with increase in flow rate.

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Modeling and parametric optimization of grinding process using flower pollination algorithm

Majumdar,

Mandal,

Singh

2024

Recent Trends in Swarm Intelligence Enabled Research for Engineering Applications

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The use of computational fluid dynamics in the analysis of fluid flow and thermal aspects in grinding

Cited by 9 publications

References 24 publications

Heat flux distribution and temperature prediction model for dry and wet cylindrical plunge grinding

Heat flux distribution and temperature prediction model for dry and wet cylindrical plunge grinding

Application of the auxiliary wheel cleaning jet in the plunge cylindrical grinding with Minimum Quantity Lubrication technique under various flow rates

Modeling and parametric optimization of grinding process using flower pollination algorithm

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