Finite Element Research of Cup Wheel Grinding Heat Based on Trochoid Scratch Model

Grinding is a highly precise machining process. However, excessive temperatures during grinding can result in adverse thermal effects on the machined material. In this study, cup wheel grinding was analyzed using a model that represents heat generation as a trochoid discrete heat source formed by the interactions between abrasive particles and the workpiece surface. With this approach, certain assumptions were made to facilitate analysis, including the modeling of abrasive grains as rigid point heat sources. Finite element simulations and experimental validations based on the trochoid model were conducted using COMSOL 6.2 software. These analyses evaluated the thermal behavior of cup wheel grinding under varying wheel speeds and feed rate ratios. The results revealed an asymmetrical distribution of the temperature field in cup wheel grinding. By examining both surface and subsurface temperature fields, this study provided a more comprehensive understanding of grinding heat. Furthermore, this investigation explored the influence of trochoid trajectories and process parameters on the temperature field, highlighting intersection and curvature thermal effects. These findings contribute valuable analytical methods and theoretical insights for controlling grinding heat in precision machining processes.