Abstract
In previous studies, the improvement of the useful flow and flow rate of grinding fluid has been investigated via modeling, simulation, and experiment. Optimized grinding parameters have been achieved. A detailed assessment of the improvement in the useful flow rate of grinding fluid, which optimizes the grinding fluid supply, has been published in the International Journal of Advanced Manufacturing Technology (Li et al. Int J Adv Manuf Technol 75:1587–1604, 2014). Then, a detailed experimental study on the improvement in the useful flow rate of grinding fluid has been published in the International Journal of Advanced Manufacturing Technology (Li et al. Int J Adv Manuf Technol 1–10. doi:10.1007/s00170-015-7230-z, 2015), in which the influence of grinding wheel speed, grinding fluid jet velocity, particle size, and bulk porosity on useful flow and useful flow rate was analyzed. In this paper, a new method of air scraper is presented and simulated with focus on the air boundary layer and reflux around the grinding wheel. In view of the influence of the gas barrier of grinding wheels on the effective supply of grinding fluid, the effect of the scraper on the gas barrier layer was analyzed through the grinding flow field simulation under unified grinding parameters. Using the air scraper to destroy the gas barrier layer is proposed, and a supply scheme is designed to improve the useful flow rate. Results show that using the scraper has a certain effect on the weakening of the grinding gas barrier layer. In the grinding process, using the scraper can reduce the obstacles to grinding fluid supply, thereby improving the useful flow of grinding fluid into grinding wheel workpieces. The distance between the front end of the plane scraper and the grinding wheel is 10 μm, with a large circular boot-shaped nozzle. Alternatively, the distance between the front end of the nozzle and the grinding wheel surface is 50 μm, which can increase the useful rate of flow of grinding fluid.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Nguyen TA, Butler DL (2005) Simulation of precision grinding process, part 1: generation of the grinding wheel surface. Int J Adv Manuf Technol 45(11):1321–1328
Hou YL, Li CH, Zhang DK, Jia DZ, Wang S (2014) Grinding temperature with nanoparticle jet minimum quantity lubrication. Recent Pat Mech Eng 7(2):149–161
Malkin S, Guo C (2007) Thermal analysis of grinding. CIRP Ann Manuf Technol 56(2):760–782
Brinksmeier E, Aurich JC, Govekar E (2006) Advances in modeling and simulation of grinding processes. CIRP Ann Manuf Technol 55(2):667–697
Ebbrell S, Woolley NH, Tridimas YD, Allanson DR, Rowe WB (2000) The effects of cutting fluid application methods on the grinding process. Int J Mach Tools Manuf 40(2):209–223
Mao C, Zou HF, Zhou X, Huang Y, Gan HY, Zhou ZX (2014) Analysis of suspension stability for nanofluid applied in minimum quantity lubricant grinding. Int J Adv Manuf Technol 71:2073–2081
Frank C, Wojciech Z, Edwin F (2004) Fluid performance study for groove grinding a nickel-based superalloy using electroplated cubic boron nitride (CBN) grinding wheels. J Manuf Sci Eng 126(3):451–458
Gao Y, Tse S, Mak H (2003) An active coolant cooling system for applications in surface grinding. Appl Therm Eng 23(5):523–537
Mao C, Zou HF, Huang Y, Li YF, Zhou ZX (2013) Analysis of heat transfer coefficient on workpiece surface during minimum quantity lubricant grinding. Int J Adv Manuf Technol 66:363–370
Morgan MN, Jackson AR, Wu H, Baines-Jones V, Batako A, Rowe WB (2008) Optimisation of fluid application in grinding. CIRP Ann Manuf Technol 57(1):363–366
Winter M, Li W, Kara S, Herrmann C (2014) Stepwise approach to reduce the costs and environmental impacts of grinding processes. Int J Adv Manuf Technol 71(5-8):919–931
Weinert K, Inasaki I, Sutherland JW (2004) Dry machining and minimum quantity lubrication. Ann CIRP 53(2):323–349
Park KH, Olortegui YJ, Yoon MC (2010) A study on droplets and their distribution for minimum quantity lubrication (MQL). Int J Mach Tools Manuf 50(9):824–833
Donaldson K, Li XY, MacNee W (1998) Ultrafine (nanometer) particle mediated lung injury. J Aerosol Sci 29(5):553–560
Kaliszer H, Trmal G (1975) Mechanics of grinding fluid delivery. SME Tech. Paper
Campbell JD (1993) An investigation of the grinding fluid film boiling limitation. Technical papers-Society of Manufacturing Engineers-all series
Campbell JD (1995) Optimized coolant application. Technical papers- Society of Manufacturing Engineers-all series
Ganesan M, Guo C, Malkin S (1995) Measurement of hydrodynamic forces in grinding. Transactions-North American Manufacturing Research Institution of SME 103–108
Ganesan M, Guo C, Ronen A (1996) Analysis of hydrodynamic forces in grinding. Transactions-North American Manufacturing Research Institution of SME 105–110
Chang CC, Wang SH, Szeri AZ (1996) On the mechanism of fluid transport across the grinding zone. J Mech Des 118(3):332–338
Klocke F, Baus A, Beck T (2000) Coolant induced forces in CBN high speed grinding with shoe nozzles. CIRP Ann Manuf Technol 49(1):241–244
Hryniewicz P, Szeri AZ, Jahanmir S (2001) Application of lubrication theory to fluid flow in grinding: part I-flow between smooth surfaces. J Tribol 123(1):94–100
Hryniewicz P, Szeri AZ, Jahanmir S (2001) Application of lubrication theory to fluid flow in grinding: part II—influence of wheel and workpiece roughness. J Tribol 123(1):101–107
Guo C, Malkin S (1992) Analysis of fluid flow through the grinding zone. J Eng Ind ASME 114(2):427–434
Engineer F, Guo C, Malkin S (1992) Experimental measurement of fluid flow through the grinding zone. J Eng Ind 114(4):61–66
Gviniashvili V, Webster J, Rowe B (2005) Fluid flow and pressure in the grinding wheel-workpiece interface. J Manuf Sci Eng 127(1):198–205
Gviniashvili V, Rowe WB, Morgan MN (2004) Useful flowrate based on grinding power. J Key Eng Mater 257–258:333–338
Gviniashvili V, Woolley NH, Rowe WB (2004) Useful coolant flowrate in grinding. Int J Mach Tools Manuf 44(2):629–636
Gviniashvili V, Webster J, Rowe B (2005) Fluid flow and pressure in the grinding wheel-workpiece interface. Trans ASME 127(2):198–205
Li CH, Hou YL, Fang Z (2011) Analytical and experimental investigation of grinding fluid hydrodynamic pressure at wedge-shaped zone. Int J Abras Technol 4(2):140–155
Li CH, Hou YL, Xiu SH, Cai GQ (2008) Model and simulation of slurry velocity and hydrodynamic pressure in abrasive jet finishing with grinding wheel as restraint. Key Eng Mater 375–376:449–453
Li CH, Cai GQ, Xiu SC (2007) Hydrodynamic pressure modeling and verification of contact zone on abrasive jet finishing with grinding wheel as restraint. Acta Armamentarii 28(2):202–205
Han ZL, Li CH (2013) Theoretical modeling and simulation of airflow field near grinding wheel. Int J Control Autom 6(4):145–155
Li CH, Han ZL (2013) Modeling and simulation of the airflow field in wedge-shaped zone during the high-speed grinding. Int J Abras Technol 6(2):114–131
Li CH, Zhang XW, Zhang Q, Wang S, Zhang DK, Jia DZ, Zhang YB (2014) Modeling and simulation of useful fluid flow rate in grinding. Int J Adv Manuf Technol 75(9-12):1587–1604
Zheng JY, Li N, Jiang ZF (2009) Application study on two-phase flow field properties of grinding fluidic jet. Mach Tool Hydraul 37(1):20–23
Wang S, Li CH, Zhang DK, Jia DZ, Zhang YB (2014) Modeling the operation of a common grinding wheel with nanoparticle jet flow minimal quantity lubrication. Int J Adv Manuf Technol 74(5-8):835–850
Morgan MN, Barczak L, Batako A (2012) Temperatures in fine grinding with minimum quantity lubrication (MQL). Int J Adv Manuf Technol 60:951–958
Brinksmeier E, Minke E (1993) High-performance surface grinding—the influence of coolant on the abrasive process. Ann CIRP 42/1:367–370
Engineer F, Guo C, Malkin S (1992) Experimental measurement of fluid flow through the grinding zone. ASME J Eng Ind 114:61–66
Chang CC (1997) An application of lubrication theory to predict useful flow-rate of coolant on grinding porous media. Tribol Int 30(8):575–581
Jia DZ, Li CH, Zhang YB, Zhang DK, Zhang XW (2015) Experimental research on the influence of the jet parameters of minimum quantity lubrication on the lubricating property of Ni-based alloy grinding. Int J Adv Manuf Technol 1–14
Mao C, Tang XJ, Zou HF, Zhou ZX, Yin WW (2012) Experimental investigation of surface quality for minimum quantity oil–water lubrication grinding. Int J Adv Manuf Technol 59(1–4):93–100
Schumack MR, Chung J-B, Schultz WW (1991) Analysis of fluid flow under a grinding wheel. Trans ASME 113(5):190–197
Mandal B, Das GC, Das S, Banerjee S (2014) Improving grinding fluid delivery using pneumatic barrier and compound nozzle. Prod Eng 8(1-2):187–193
Mandal B, Singh R, Das S, Banerjee S (2011) Improving grinding performance by controlling air flow around a grinding wheel. Int J Mach Tools Manuf 51(9):670–676
Mandal B, Singh R, Das S, Banerjee S (2012) Development of a grinding fluid delivery technique and its performance evaluation. Mater Manuf Process 27(4):436–442
Heinemann R, Hinduja S, Barrow G, Petuelli G (2006) Effect of MQL on the tool life of small twist drills in deep-hole drilling. Int J Mach Tools Manuf 46:1–6
Li CH, Zhang Q, Zhang Q, Wang S, Zhang DK, Jia DK, Zhang YB, Zhang XW (2015) Useful fluid flow and flow rate in grinding: an experimental verification. Int J Adv Manuf Technol 1–10. doi:10.1007/s00170-015-7230-z
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Zhang, Y., Li, C., Zhang, Q. et al. Improvement of useful flow rate of grinding fluid with simulation schemes. Int J Adv Manuf Technol 84, 2113–2126 (2016). https://doi.org/10.1007/s00170-015-7864-x
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-015-7864-x