Heat generation and heat transfer in cylindrical grinding process - a numerical study

Grinding is the most common abrasive machining process and in many cases the last of the series of machining operations. Compared to other machining processes grinding requires very high-energy input per unit of volume of material removal. The chip removal process consists of rubbing, plowing and metal removal. The frictional resistance encountered between work material, the tool, and the chip tool interface and the resistance to deformation during shearing of chips contributes to a rise in temperature and the cutting zone. The temperature generated is not only quite high but the temperature gradients are also severe. Under abusive grinding conditions, the formation of the heat-affected zone was observed which damages the ground surfaces of the workpieces. The present work aims at optimizing the amount of heat generation and modeling the temperature rise between wheel and work contact zone in a cylindrical grinding process so as to achieve better surface integrity in AISI 3310, AISI 6150, and AISI 52100 steel materials. Taguchi's methodology a powerful tool in design of experiments for quality is used for optimization process.