A multiscale simulation approach for grinding processes: grain engagement, heat generation, and coolant interaction

Abstract Grinding processes are governed by microscopic interactions between the workpiece, grinding wheel, and coolant. Even under constant process parameters, microscopic fluctuations in the contact zone cause variations in thermomechanical load and workpiece quality. While fully resolving these effects in simulations would improve process understanding, the computational cost is prohibitive. This article presents a multiscale simulation approach that incorporates local microscopic phenomena and uncertainties into an overall grinding process simulation. A microscale material removal simulation predicts local grain interactions, grinding forces, heat input, and surface topographies. These results are scaled to the macroscopic contact zone and used as inputs for a thermo-fluid model that computes flow profiles and temperature distributions in the workpiece, wheel, and coolant. The influence of cooling parameters and wheel condition is analysed and validated on a creep feed grinding process through comparison with experimental data and analytical models.