Temperature Field Simulation In Ultra-high Speed Grinding Of Metallic Materials Using Finite Element Method

Ultra-high speed grinding, because of its higher productive efficiency, better surface finishing than general grinding, is the current trend of grinding technology in the 21 century. The specific grinding energy is very high, most of the energy will flow into the workpiece, which will make temperature of the grinding zone raise up. Concentrated heat input leads to temperature rise on the surface of workpiece may lead to thermal damage to workpiece and grinding wheel. Therefore, it is very important and realistic to research the metallic material grinding temperature for the thermal principle exploring and the grinding surface quality controlling.In this paper, the ultra-high speed grinding temperature field has been analyzed with the analytical method firstly. Two thermal models were presented for ultra-high speed grinding. They were respectively uniform heat flux distribution model and triangular heat flux distribution model. The maximum contact temperatures during the ultra-high speed grinding were studied by experiment and theory calculationSecondly, by means of the finite element method (FEM) the equations of the stable and the transient temperature distribution are deduced and according to these the grinding temperature distribution model is got, which provides the theory foundation for the further research of the grinding temperature.Third, computational model for thermal analysis is established. The paper simplifies the heat source of contact area in grinding as rectangle heat source. As for the models, they are divided into hexahedron and solid thermal elements by making use of the finite element analysis software-ANSYS10.0. Thereby, the computational models of three dimensions that can describe the true status are built for dynamic simulation. Focus on the FEM, the trend of ultra-high speed grinding temperature field of the two metallic material 45#carbon steel and 40Cr alloy steel are analyzed in detailed with the grinding parameters such as wheel speed, cut depth and table speed.Lastly, the maximum contact temperatures during the grinding were studied by experiment on a super high speed grinder. The merits and processes using thermocouple techniques are discussed in detail. The research indicated that, with the finite element analysis software ANSYS, the simulation analysis for ultra-high speed grinding temperature field only has few error compared with the experimental results, and has more accurate reflects of grinding temperature field than the analytical solution.The production of this paper opens out the internal rule of ultra-high speed grinding temperature field of metallic material; it is helpful to set up perfect ultra-high speed grinding basic system info, and it also has certain guiding sense for the manufacturing.