Into the boundary layer behavior of segmented grinding wheels and its illustration on Ti6Al4V

Segmented grinding wheels, with active abrasive regions and passive slots, have been reported as a promising choice for controlling the grinding force via an intermittent cutting scheme. With an appropriate selection of feed and other operating variables, segmented grinding could mark its merits of improved thermal performance and grinding efficiency, typically in difficult-to-machine aerospace materials. However, the formation of a boundary layer around a rotating grinding wheel is always a barrier to effective cutting fluid delivery in the grinding zone. This article attempts to investigate the boundary layer characteristics of segmented grinding wheels, typically with a comparison of 8-segmented and 32-segmented grinding wheels with a non-porous electroplated structure and its comparison with traditional porous grinding wheel configuration. The regression model proposed in this article can predict boundary layer thickness and tangential air velocity in the grinding zone during the rotation of the wheel. A closer look at flow aspects has been covered using computational fluid flow modeling/simulation, followed by experimental assessments through particle image velocimetry and shadowgraphs. The influence of segmentation and its configuration (typically the number of segments) have been illustrated through a case study of wet grinding on Ti6Al4V.