Thermal analysis of high efficiency deep grinding

Regimes of deep grinding range from creep grinding conducted at low workspeeds to High Efficiency Deep Grinding (HEDG) at fast workspeeds. At intermediate depths of cut, grinding is likely to be impossible due to high temperatures and damage to the workpiece and wheel. Analytical techniques for the determination of temperatures in deep grinding processes are discussed. An explanation is proposed for why it is possible to work efficiently at these two extremes of removal rate without experiencing the severe problems experienced in the intermediate range. Methods are required for determining the transition conditions so that process engineers can select process conditions for efficient material removal and high quality of manufactured products using high efficiency deep grinding. This paper provides a method for order of magnitude estimation of temperatures. It is proposed that the angle of inclination of the contact plane is an important parameter for the achievement of high workspeeds. It is argued that workpiece melting provides an ultimate boundary for energy dissipation within the workpiece. (C) 2000 Elsevier Science Ltd. All rights reserved.