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Thermal model for surface grinding application

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Due to the characteristics of the grinding process, thermal damage may occur in the workpiece surface, resulting in the rejection of a component and considerably increasing the production costs. This study aims to analyze the heat fluxes, energy partition, and temperatures during surface grinding process with both conventional and MQL lubrication. Through the proposed analysis, the heat fluxes and maximum temperature can be predicted, enabling the avoidance of thermal damages and increasing the efficiency of the process. A comparison between the calculated and experimental value has shown that the difference is acceptable for various situations, in the order of 4.72% for the conventional method and 7.38% for the MQL method. A thermal model was developed. The transient two-dimensional heat diffusion equation was discretized by finite volume method in space and explicit discretized in time. The heat fluxes were estimated using inverse problem technique of heat transfer aiming the obtainment of the temperature of certain workpiece points. A comparison of the methods of lubrication showed that the conventional method was way more efficient than MQL, presenting considerably lower total heat flux and maximum reached temperature and any kind of thermal damage wasn’t observed. On the other hand, thermal damage occurred in the workpieces. Also, clogging phenomenon in the grinding wheel surface after the process in MQL condition was observed.
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ORIGINAL ARTICLE
Thermal model for surface grinding application
Lucas de Martini Fernandes
1
&José Claudio Lopes
1
&Fernando Sabino Fonteque Ribeiro
1
&Rubens Gallo
2
&
Henrique Cotait Razuk
2
&Luiz Eduardo de Angelo Sanchez
1
&Paulo Roberto de Aguiar
3
&Hamilton José de Mello
1
&
Eduardo Carlos Bianchi
1
Received: 14 February 2019 /Accepted: 4 July 2019 /Publ ished online: 24 July 2019
#Springer-Verlag London Ltd., part of Springer Nature 2019
Abstract
Due to the characteristics of the grinding process, thermal damage may occur in the workpiece surface, resulting in the rejection
of a component and considerably increasing the production costs. This study aims to analyze the heat fluxes, energy partition, and
temperatures during surface grinding process with both conventional and MQL lubrication. Through the proposed analysis, the
heat fluxes and maximum temperature can be predicted, enabling the avoidance of thermal damages and increasing the efficiency
of the process. A comparison between the calculated and experimental value has shown that the difference is acceptable for
various situations, in the order of 4.72% for the conventional method and 7.38% for the MQL method. A thermal model was
developed. The transient two-dimensional heat diffusion equation was discretized by finite volume method in space and explicit
discretized in time. The heat fluxes were estimated using inverse problem technique of heat transfer aiming the obtainment of the
temperature of certain workpiece points. A comparison of the methods of lubrication showed that the conventional method was
way more efficient than MQL, presenting considerably lower total heat flux and maximum reached temperature and any kind of
thermal damage wasnt observed. On the other hand, thermal damage occurred in the workpieces. Also, clogging phenomenon in
the grinding wheel surface after the process in MQL condition was observed.
Keywords Surface grinding .Thermal model .MQL lubrication
1 Introduction
In many industrial applications, the grinding process is fre-
quently the final step in the process chain towards finished
workpieces. This involves two aspects: firstly, being the ulti-
mate process, the appearance of the ground areas is presented
to the costumer. In this way, the tolerance for faults and all
other deviations from the intended surface characteristics is
*Eduardo Carlos Bianchi
eduardo.bianchi@unesp.br
Lucas de Martini Fernandes
lucas-asewas@hotmail.com
José Claudio Lopes
jclaudio.lopes@hotmail.com
Fernando Sabino Fonteque Ribeiro
fernando_fonteque@yahoo.com.br
Rubens Gallo
rubensgallo@utfpr.edu.br
Henrique Cotait Razuk
cotait@utfpr.edu.br
Luiz Eduardo de Angelo Sanchez
luiz.sanchez@unesp.br
Paulo Roberto de Aguiar
aguiarpr@unesp.br
Hamilton José de Mello
hamilton@unesp.br
1
Department of Mechanical Engineering, College of Engineering,
College of Engineering, São Paulo State University (UNESP),
Bauru, SP 17033-360, Brazil
2
Department of Mechanical Engineering, Federal University of
Technology Paraná (UTFPR), Cornélio Procópio, PR 86300-000,
Brazil
3
Department of Electrical Engineering, College of Engineering, o
Paulo State University (UNESP), Bauru, SP 17033-360, Brazil
The International Journal of Advanced Manufacturing Technology (2019) 104:27832793
https://doi.org/10.1007/s00170-019-04101-6
Content courtesy of Springer Nature, terms of use apply. Rights reserved.
... Throughout the grinding operation, several cutting edges come into contact with the workpiece, deforming and scraping over its surface. As a result, much of the process energy is dissipated as heat, causing the temperature in the cutting zone to increase [9][10][11]. The heat generated is so intense that if it is not mitigated, several problems can arise in grinding, ranging from accelerated wear of the grinding wheel due to the weakening of the bond, microstructural modification of the workpiece material, to even clogging of the grinding wheel pores, preventing the removal of the chips, thus damaging the workpiece [12]. ...
... This disadvantage is due to the lower ability to dissipate heat from the compressed air in MQL compared to the fluid used in the conventional method. Therefore, there may be greater wear on the grinding wheels and thermal damage to the workpiece [10,44]. ...
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... This extreme heat generated during the process significantly hinders the workpiece's quality (Sinha et al., 2023). This is highly disadvantageous because the workpiece has already been produced to its entire value, and scrapping it costs money (de Martini Fernandes et al., 2019). Also, Surface Roughness (Ra) is a crucial quality characteristic that directly impacts the tribological performance, wear resistance, and useful life of many parts and components (Ghosh et al., 2019). ...
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... (b) stainless steel [14]; (c) AA6060 aluminum alloy [15]; (d) AZ31B magnesium alloy [16]; (e) Ti-6Al-4V [17]; (f) CuSn10 bronze [18]; (g) chips produced without chip breaker [19]; (h) chips of aluminum created by the turning tool's chips breaker [19]; (i) AA6060 aluminum alloy [15]; j) AC4CH aluminum (alloy [20]; (k) modulation-assisted drilling of stainless steel [21]; (l) conventional drilling of stainless steel [21]; (m) low carbon steel [22]; (n) AA1050 aluminum alloy [23]; (o) AISI 4340 steel [24]; (p) low alloy steel [25]. ...
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... Nickel-base superalloy as Inconel 718 is a well-known difficult-to-machine material due to low thermal conductivity, and chemical reactivity, which leads to high temperature in the cutting zone [7]- [9]. The extreme energy, which is expended by the grinding, generates high heat during the process, and consequently, the temperature of the workpiece surface and subsurface is elevated [10], [11] Oliveira et al. [12] propose that as heat increases, it accelerates the cutting tool wear, which affects the final quality of the machined surface [13], [14]. ...
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