Application of Lubrication Theory to Fluid Flow in Grinding: Part II—Influence of Wheel and Workpiece Roughness

[+] Author and Article Information
P. Hryniewicz, A. Z. Szeri

Department of Mechanical Engineering, University of Delaware, Newark, DE 19716-3140

S. Jahanmir

Ceramics Division, National Institute of Standards and Technology, Gaithersburg, MD 20899-8520

J. Tribol 123(1), 101-107 (Sep 26, 2000) (7 pages) doi:10.1115/1.1331278 History: Received February 23, 2000; Revised September 26, 2000
Copyright © 2001 by ASME
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Schumack,  M. R., Chung,  J. B., Schultz,  W. W., and Kannatey-Asibu,  E., 1991, “Analysis of Fluid Flow Under a Grinding Wheel,” ASME J. Eng. Ind., 113, pp. 190–197.
Ganesan,  M., Guo,  C., Ronen,  A., and Malkin,  S., 1996, “Analysis of Hydrodynamic Forces in Grinding,” Trans. NAMRI/SME, 24, pp. 105–110.
Hryniewicz,  P., Szeri,  A. Z., and Jahanmir,  S., 2001, “Application of Lubrication Theory to Fluid Flow in Grinding: Part I—Flow Between Smooth Surfaces,” ASME J. Tribol., 123, pp. 94–100.
Patir,  N., and Cheng,  H. S., 1978, “An Average Flow Model for Determining Effects of Three-Dimensional Roughness on Partial Hydrodynamic Lubrication,” ASME J. Lubr. Technol., 100, pp. 12–17.
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Hryniewicz, P., 1999, “Coolant Flow in Grinding with Non-Porous Wheels,” Ph.D. thesis, University of Delaware, Newark, DE.
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Schematic representation of the minimum nominal gap size in the spark-out position hs
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Schematic representation of the wheel crown and the wheel-workpiece configuration
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Wheel crown as determined by surface profile measurement across a plunge-ground silicon nitride specimen
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Schematic showing the grinding geometry and the coordinate system used in formulation of the problem
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Maximum pressure pmax as a function of gap size hg for oil and wheel speeds Vs=10 m/s and 20 m/s. Grinding wheel, toil=26.4°C,Qnoz=10 l/min.
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Predicted ratio of the maximum pressure pmax and the effective flow rate Qef for the grinding wheel to the corresponding values for a smooth wheel, as a function of the dimensionless parameter hg1,2. The vertical line indicates the spark-out position.
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Influence of surface roughness on the developed hydrodynamic pressure for grinding fluid. Experimental results for the grinding wheel at hg=56 μm compared with smooth wheel results at hg=50 μm: (a) centerline pressure p as a function of position x for Vs=20 m/s; (b) maximum pressure pmax as a function of the wheel speed Vs.
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Ratio of the maximum pressure during a grinding pass to the corresponding maximum pressure during a spark-out pass. The ratio determined for consecutive grinding passes in three cases: grinding fluid and depth of cut of a=5 μm, oil and a=5 μm, and oil and a=10 μm.Vs=20 m/s,Qnoz=10 l/min.
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Areal autocorrelation functions of the workpiece and the grinding wheel roughness height: (a) workpiece; (b) grinding wheel. Isolines at the levels of 0.2 and 0.5 are also shown.
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Centerline pressure p as a function of position x for oil and gap size hg=hs=46 μm (spark-out). Grinding wheel, toil=26.4°C,Qnoz=10 l/min,Vs=10 m/s, 20 m/s, and 30 m/s.
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Maximum pressure pmax as a function of wheel speed Vs for oil, and a range of gap sizes: hg=hs,hs+10 μm,hs+30 μm, and hs+60 μm (where hs=46 μm). Each point is an average of three measurements, and error bars indicate the standard deviation. Grinding wheel, toil=26.4°C,Qnoz=10 l/min.



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