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CFD and experimental investigation of channel diameter effects in structured internally cooled grinding wheels

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Resumo:Efficient cooling and lubrication are critical in grinding due to the high specific energy and limited contact area involved. Conventional external methods often fail to penetrate the air barrier formed by the rotating wheel, leading to excessive heat generation and reduced process stability. To overcome this limitation, this study investigates vitrified alumina grinding wheels with internal cooling channels designed for directed fluid delivery. Three structured configurations were developed, all with identical total outlet area (similar to 54 mm(2)) but different channel diameters (0.6, 1.0, and 1.5 mm), to isolate the effect of channel size on fluid flow and grinding behavior. Computational fluid dynamics (CFD) simulations were performed to assess outlet velocity and surface coverage, while grinding tests quantified tangential and normal forces, temperature variation (Delta T), force ratio (F-t/F-n), and specific grinding energy. Narrow channels provided uniform surface coverage but limited jet velocity due to higher hydraulic resistance, whereas wider channels enhanced outlet velocity at the expense of flow uniformity. The intermediate configuration (& Oslash; 1.0 mm) yielded the most balanced performance, achieving up to 38 % lower tangential force and 41 % lower temperature than the & Oslash; 0.6 mm design, while maintaining low specific energy across all depths of cut. Correlation between CFD and experimental results confirmed that both jet intensity and spatial distribution govern cooling and lubrication efficiency. These insights support the design of more efficient and sustainable grinding wheels through tailored channel geometries.
Autores principais:Costa, Sharlane
Outros Autores:Capela, Paulina; Sousa, Maria; Hassui, Amauri; Ribeiro, J.E.; Pereira, Mário; Soares, Delfim
Assunto:Grinding performance Internal cooling system Structured grinding wheel Computational fluid dynamics (CFD) Sustainable manufacturing
Ano:2026
País:Portugal
Tipo de documento:artigo
Tipo de acesso:acesso aberto
Instituição associada:Instituto Politécnico de Bragança
Idioma:inglês
Origem:Biblioteca Digital do IPB

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