Theoretical modeling, simulation and experimental validation of high-shear and low-pressure grinding heat using ball-end body-armor-like abrasive tool

Abstract

To clarify the mechanisms of heat dissipation and distribution in high-shear and low-pressure (HSLP) grinding using a ball-end body-armor-like abrasive tool, a theoretical temperature field model was established. Based on the HSLP grinding mechanism, the convective heat transfer coefficient was determined by integrating fluid dynamics with heat transfer theory. The influence of cutting film flow velocity on its heat dissipation capacity was revealed. A heat source model was established using the Gaussian heat source distribution. The grinding temperature was analysed in relation to spindle rotational speed, feed speed, and normal force. A comparison between the analytical model and numerical simulation was conducted, followed by experimental validation, which confirmed the model's accuracy. The results indicated that the trends predicted by the theoretical analysis were consistent with those observed in finite element simulations and experimental measurements. Specifically, the theoretical grinding temperature was found to increase with spindle rotational speed, decrease with higher feed rates, and rise with increasing normal force. The theoretical analysis yielded an average error of 4.97%, demonstrating the model's reliability. This study advanced the theoretical understanding of thermal behavior in HSLP grinding.