Temperature and force modeling on grinding

Official URL: http://risc01.sabanciuniv.edu/record=b1649215 (Table of Contents)

Grinding operations are commonly used in machining industry as they offer high precision level for applications such as increasing the surface quality of parts, and even machining of hard alloy in the aviation and space technology, automotive, biomedical equipment and electronics. Super abrasive grinding operations has gained importance through increasing usage of super alloys in these sectors. Excessive temperature rise occurs on workpiece during hard metal grinding, which can cause residual stresses, micro cracks, surface burns etc. Process modeling is crucial for examining these effects to control them within optimization of grinding parameters in less costly and less time consuming way. Investigation of grinding operations has been held by researchers since the industrial revolution, and it became state of the art with its stochastic nature. At present there is no suitable method to identify process temperature and forces without calibration and experimental data. The advantage of these studies is that consistent model results according to the calibrated data, but nevertheless, the wide range of adaptability remained limited. The goal of this thesis is to define the geometrical identification of grinding operations and usage of these into thermomechanical and temperature modeling of the process as a whole model to reduce dependence on calibration via experimental data. In this content, the hypotheses of this study are that temperature calibration on the thermomechanical model can be solved via iteratively with the calculation of attained and resultant temperature values in it. Furthermore, geometrical approaches for wheel and grain geometry is crucial to develop comprehensible force and temperature modeling. Temperature and force parameters were investigated by the established models and experimental data. After all, comprehensive process models were established for wide range of usage. This thesis is divided into four chapters in these directions; starting with the geometrical investigation and followed by force modeling and temperature modeling and finally a review of them in the experimental verifications and discussions.