Cut-off Grinding of Hardened Steel Wires - Modelling of Heat Distribution

Cut-off grinding is an applied machining technology to separate high strength steel bars. Due to the high heat generation and geometrical boundary conditions, diverse thermally induced defects occur in the machined part, for example grinding burn and burr formation. Based on FE analysis, the heat distribution inside the steel bar was calculated for different cutting conditions with the goal of minimizing these manufacturing errors. The critical maximum workpiece temperature decreases up to forty-eight percent by adapting the cutting parameters and cooling strategy. The numerical model and calculated temperature distributions were verified via experimental analysis.