Analytic solution and numerical validation of the transient regime in dry surface grinding

Abstract In the framework of Samara–Valencia model for heat transfer in dry surface grinding, analytical expressions for the time-dependent temperature field of the workpiece during the transient regime in which the wheel is engaged (cut-in) and disengaged (cut-out) from the workpiece are calculated. The main assumption we consider is a constant heat flux profile along the contact zone between the wheel and the workpiece. According to the analytical expression obtained for the temperature field, a closed-form expression for the maximum temperature during the cut-in transient regime has been obtained. Further, a very rapid method for the numerical evaluation of maximum temperature during the cut-out is described. This maximum temperature is responsible of the thermal damage of the workpiece. Experimental evidence shows that the thermal damage risk is greater during the cut-out transient regime. The present analytical model reproduces this experimental feature. Finally, the analytical results have been numerically validated using FEM analysis and are intended to be very useful for the monitoring of the online grinding process in order to avoid thermal damage.