Heat Flux Distribution Model in the Cylindrical Grinding Contact Area

A heat flux distribution model was proposed based on Rayleigh curve for the contact area in cylindrical plunge grinding. In this paper, an embedded thermocouple which can be grind was used to measure the workpiece surface temperature. Based on the sequential algorithm, an inversed heat transfer method was built to calculate the heat flux by using the measured temperature. The results indicated that the heat source along the contact area is asymmetric and more conformed with Rayleigh curve by comparing to the other three typical heat flux models (quadratic curve, left-angled triangle and rectangular uniform). The ratio of the grinding heat transported to the workpiece in the grinding contact area is a critical factor for calculating grinding temperatures. The energy partition to the workpiece was obtained by the experimental grinding temperature and grinding force. The actions of the abrasive grains on the workpiece surface were reflected by the changes of the grinding temperature signals in high sampling rate. The real contact length can be deduced by the time interval that the temperature sparks appeared. The grinding force monitored by a dynamometer equipped on the rear center of the grinding machine. Finally, the prediction of workpiece surface temperature for cylindrical plunge grinding can be realized by using the energy partition to the workpiece, the real contact length, Rayleigh curve heat flux distribution model and the tangential grinding force.