Modeling And Simulation And Experimental Study Of Useful Flowrate Of Grinding Fluid

The energy consumption of removing unit volume of material during grindingprocess is much larger than the other cutting methods, with a large amount of heatgenerating in the grinding zone, which transfers into the chips, tools and workpieces,resulting a great impact on the workpiece surface quality and performance. In order toreduce the temperature of the grinding zone, the methods of pouring liquid that supplieslarge flow grinding fluid to the grinding zone is widely used in the production. However,this method makes it difficult for grinding fluid into the grinding zone because of gasbarrier formed under high speed rotation of the wheel, useful flow that actually flowthrough the gap between the grinding wheel and the workpiece is only5%-40%of jetflow, a large number of grinding fluid can not enter the gap, grinding fluid is only play arole of cooling the workpiece. The flow that grinding fluid actually flow through theinterface between grinding wheel and workpiece is called useful flow. The ratio ofuseful flow to jet flow is called the useful flow rate. Only useful flow can providelubrication to the grinding activities, prevent wheel wear and clogging, maintain a lowsurface roughness and prevent to produce high grinding temperature. So the research ofgrinding fluid useful flow changing along with the grinding parameters is of greatsignificance.This article firstly simulated the grinding airflow field, then created an useful flowmathematical model and simulated the grinding gas-liquid two phase flow field. Basedon the above simulation results, the design plan of increasing grinding fluid useful flowrate was proposed, and the improvement and optimization for the design plan was madeon the basis of the simulation analysis. Finally, the related confirmatory experimentswere developed. The main contents include:1. Theoretical modeling and simulation research of the grinding airflow field hadperformed, in which analyzed the speed, pressure and the distribution of the return flowin the airflow field of grinding zone, that provided theoretical guidance for theoptimization of grinding fluid supply.2. The mathematical model of the useful flow rate under the condition of plane grinding with the methods of pouring liquid was established, and simulation study wasconducted. The simulation mainly analyzed the influence of grinding wheel speed, fluidjet speed, the minimum clearance in the grinding zone, and nozzle clearance width tothe grinding fluid useful flow and the useful flow rate.3. The air scraper was used to destroy the gas barrier layer around the grindingwheel, and the influence of air scraper to the gas barrier layer was analyzed by grindingairflow field simulation. Based on the above analysis, the plan of improve grinding fluiduseful flow rate was designed, and its effect was discussed according to the grindinggas-liquid two phase flow field simulation, and the best solution was determined on thatbasis.4. The experiment was conducted to verify the theoretical analysis and simulationresults of grinding fluid useful flow rate. The experiment studied the influence ofgrinding wheel speed, grinding fluid jet speed and grinding wheel granularity on usefulflow and useful flow rate. The results show that the experiment and simulation resultsare basically consistent, the correctness of the theoretical analysis and simulationresearch was verified.