Temperature Field Research In The Grinding Of Nickel-Based Superalloy Using Pressurized Internal Cooling Wheel

During the grinding process of hard-to-cut materials(such as superalloy), the grinding energy ratio is very high, and the thermal conductivity is very poor, most of the grinding energy is converted into grinding heat and accumulated in the grinding zone, which will result in grinding burn, low material removal rate and the fast wear of grinding wheel and so on. the traditional solution is: a large amount of fluid is poured into grinding zone to achieve lubrication and cooling in the grinding process. However,the amount of fluid got into the grinding zone in the casting process is relatively little.Moreover, the coolant got into the grinding zone will occur boiling and vaporization because of the surface high temperature, and then the vapour film on the surface of grinding zone, the lubrication and cooling performance will been limited by the vapour film and gas barrier layer, and the new grinding liquid is also impeded getting into the grinding zone. Therefore, the conventional flood cooling method can not decrease the temperature of grinding zone efficiently, efficient cooling method for grinding is particularly important.The idea of internal cooling intermittent grinding technology that combine the internal cooling technology and the intermittent grinding cooling technology is proposed in this paper. The pressurized internal cooling wheel is designed and produced based on The basic principle of internal cooling intermittent grinding technology. In this paper, the superalloy is choose as the material, based on experiment research and numerical simulation analysis, the heat transfer performance to the grinding zone in the superalloy grinding by using pressurized internal cooling wheel.The main work is as follows:(1) The pressurized internal cooling wheel is designed and produced based on the basic principle of internal cooling intermittent grinding technology, based on heat source moving theory, the heat transfer model of grinding is established, the theoretical calculation is completed, and simulation turbulent model is also established.(2) Based on the heat source method, the temperature field simulation model in the grinding of superalloy by using the pressurized internal cooling wheel is established in Fluent simulation software, the effect of heat flux, rotating speed of the grinding wheel and the external pressure to grinding temperature is analyzed, and the grinding zone temperature is compared when pouring pressurized coolant into the wheel and notpouring pressurized coolant into the wheel under same heat flux.(3) The superalloy grinding experment is completed by using pressurized internal cooling wheel under three different grinding cooling ways, and grinding force and grinding temperature is measured and compared under different experimental scheme,as well as the surface roughness and machining surface morphology is measured and compared under the different experimental scheme. the cooling performance, the effect of machining surface morphology and the effect of the experimental parameter to grinding performance is discussed. the grinding zone temperature is analysed combining experiment result and simulation result under different heat flux, and the heat transfer performance to the grinding zone in the grinding is proved.