Application of Computer Simulation Technology in Grinding Temperature Field
October 10 10:16:37, 2025
Grinding is a widely used precision machining technique, often relying on trial and error due to limited understanding of the underlying mechanisms. Traditional methods for analyzing grinding temperature are typically based on single factors, making it challenging to grasp the full picture. However, with the advancement of computer technology, simulation has become an essential tool in industrial research, offering new perspectives and enabling deeper exploration of grinding processes.
Simulation allows researchers to model and predict the behavior of systems under real-world conditions. This involves creating a model, applying loads and constraints, and predicting system responses. By observing simulations, engineers can estimate real-world parameters and performance characteristics. In the context of grinding, simulation helps understand temperature changes across different input parameters, facilitating better analysis of the grinding mechanism.
To model the grinding temperature field, the finite element method is employed. The heat transfer equation governing this process is derived from the principle of energy conservation:
$$
\rho c \frac{\partial q}{\partial t} - \frac{\partial}{\partial x}(k_x \frac{\partial q}{\partial x}) - \frac{\partial}{\partial y}(k_y \frac{\partial q}{\partial y}) - \frac{\partial}{\partial z}(k_z \frac{\partial q}{\partial z}) = rQ
$$
This equation considers three types of boundary conditions: fixed temperature, heat flux, and convective cooling. By discretizing the workpiece into elements and applying thermal loads, a detailed temperature distribution can be obtained. The model accounts for both spatial and temporal variations, allowing for accurate predictions of temperature changes during grinding.
A simulation example was conducted using surface grinding. The contact zone was modeled as ABB'A', with a heat source length of approximately 1/2 of the workpiece motion direction. The simulation process involved cyclic iteration, where the thermal load was applied in small time steps, ensuring accurate representation of temperature dynamics.
For dry grinding of TC4 titanium alloy, key parameters included wheel speed (143 rpm), wheel diameter (245.2 mm), and grinding depth (0.01 mm). The resulting temperature field was visualized, showing high temperatures that could lead to burning if not controlled. In wet grinding, convection cooling reduced temperatures significantly, with results aligning closely with experimental data within a 10% error margin.
Simulation proved effective in analyzing how different parameters affect the temperature field. It also helped optimize grinding conditions, reducing the risk of burns by adjusting parameters to achieve more stable temperatures. This approach not only improves accuracy but also supports the development of advanced grinding technologies, providing a solid foundation for future research and application.