Numerical Simulation of Grinding with Realistic Representation of Grinding Wheel and Workpiece Movements: A Finite Volumes Study

Thermal models have been long established for the simulation of thermal phenomena occurring during machining processes which involve intense heat exchange, such as grinding. These models, if properly combined with experimental results and observations, can provide significantly accurate results concerning quantities that are difficult to be measured directly and lead to a deeper understanding of the occurring phenomena. The vast majority of such simulations often include simplifications such as replacement of grinding wheel with a moving heat source. In the current study, a finite volumes thermal model with explicit representation of the grinding wheel and workpiece movements is presented and cases involving the use of various machining conditions are conducted with a view to determine temperature distribution and heat affected zones within the workpiece in each case.