Analytical Modelling of Temperature in Cylindrical Grinding to Predict Grinding Burns

The direct measurement of grinding temperature is always difficult due to coolant cover and very size of work and wheel interaction zone. At the same time, high heat generation in grinding often leads to grinding burns thereby affecting surface integrity; in this context, theoretical evaluation of temperature could facilitate early detection of the grinding burns. This paper therefore presents an analytical model to evaluate grinding temperature and correlates it with the occurrence of grinding burns in terms of BNA. In general, the analytical approach involves evaluating real contact length, grinding forces and finally grinding zone temperature for the plunge cylindrical grinding. The maximum rise in grinding temperature at the surface was calculated, for the wet grinding process by considering the total heat flux entering into the grinding system. Model validation experiments have been performed to measure BNA and identify parametric conditions that produce grinding burns. The model estimate of grinding zone temperature of 631 °C is in good agreement (92%) with other research works. Further, when the calculated grinding temperature reaches beyond 631 °C, the grinding burns are observed on the work surface with a BNA value of the order of 100 mp for the micro alloyed steel. The minimum thermal damage in terms of BNA is observed at higher levels of wheel speed and spark-out time and lower levels of depth of cut.