Application of Lubrication Theory for Rough Surfaces to Fluid Flow in Grinding with Non-Porous Wheels

摘要

Creep feed grinding and high speed grinding are very attractive machining techniques for both advanced ceramics and metals, as they are often more cost-effective than a conventional grinding process. Successful implementation of these techniques relies heavily on proper application of large quantities of grinding fluid into the grinding zone. The present paper employs the modified Reynolds equation for flows between rough surfaces, in order to predict fluid behavior in the grinding zone. The proposed model is verified experimentally in terms of the developed hydro- dynamic pressure, using a resin bonded grinding wheel and straight oil. Good agreement between theory and experiment is observed in the range of parameters tested. Based on the proposed model it is shown, that the effective flow rate through the grinding zone is dominated by the shear flow. Grinding wheel topography is evaluated, and the roughness parameters which influence fluid flow are identified and determined. It is intended that the model be combined with the energy equation in order to predict the rate of cooling and the developed grinding temperatures.