TY - JOUR

T1 - Modeling the wetting behavior of grinding wheels

AU - Wichmann, Marcel

AU - Eden, Michael

AU - Zvegincev, Dennis

AU - Wiesener, Frederik

AU - Bergmann, Benjamin

AU - Schmidt, Alfred

N1 - Funding Information: Open Access funding enabled and organized by Projekt DEAL. This research was conducted within the Priority Program 2231 FLUSIMPRO. It was funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation), project number 439916647.

PY - 2023/9

Y1 - 2023/9

N2 - Helical flute grinding is an important process step in the manufacturing of cylindrical cemented carbide tools where the use of cooling lubricants is a defining factor determining process performance. Finding optimal parameters and cooling conditions for the efficient use of lubricant is essential in reducing energy consumption and in controlling properties of the boundary zone like residual stresses. Any mathematical model describing the interactions between grinding wheel, lubricant and workpiece during the process has to account for the complex microstructure of the wheel; however, this renders the identification of parameters like slip or heat exchange coefficients numerically prohibitively expensive. In this paper, results from grinding oil droplet experiments are compared with simulation results for the wetting behavior of grinding wheels. More specifically, finite element simulations of the thin-film equation are used to identify slip parameters for different grinding wheel specifications (grain size, bonding structure, wetting status). Our results show that both the bonding and the grain size have an influence on the wetting behavior. The slip parameters that we identified account for the fluid-microstructure interactions and will be used to effectively model those interactions in more complex 3D fluid-dynamic simulations via the Beavers-Joseph condition.

AB - Helical flute grinding is an important process step in the manufacturing of cylindrical cemented carbide tools where the use of cooling lubricants is a defining factor determining process performance. Finding optimal parameters and cooling conditions for the efficient use of lubricant is essential in reducing energy consumption and in controlling properties of the boundary zone like residual stresses. Any mathematical model describing the interactions between grinding wheel, lubricant and workpiece during the process has to account for the complex microstructure of the wheel; however, this renders the identification of parameters like slip or heat exchange coefficients numerically prohibitively expensive. In this paper, results from grinding oil droplet experiments are compared with simulation results for the wetting behavior of grinding wheels. More specifically, finite element simulations of the thin-film equation are used to identify slip parameters for different grinding wheel specifications (grain size, bonding structure, wetting status). Our results show that both the bonding and the grain size have an influence on the wetting behavior. The slip parameters that we identified account for the fluid-microstructure interactions and will be used to effectively model those interactions in more complex 3D fluid-dynamic simulations via the Beavers-Joseph condition.

KW - Cooling lubrication

KW - Modeling

KW - Thin-film equation

KW - Tool grinding

UR - http://www.scopus.com/inward/record.url?scp=85167639949&partnerID=8YFLogxK

U2 - 10.1007/s00170-023-12002-y

DO - 10.1007/s00170-023-12002-y

M3 - Article

AN - SCOPUS:85167639949

VL - 128

SP - 1741

EP - 1747

JO - International Journal of Advanced Manufacturing Technology

JF - International Journal of Advanced Manufacturing Technology

SN - 0268-3768

IS - 3-4

ER -