High-shear and low-pressure grinding heat with the liquid-body-armor-like ball-end abrasive tool: modeling and simulation

In the evolving field of precision machining, the demand for high-quality surface components processing is increasing rapidly. Ball-end abrasive tools, which resemble liquid body armor owing to their adaptive contact properties, hold significant promise for applications in this area. To clarify the uncertain thermal characteristics and undefined mechanisms of heat generation and dissipation associated with this tool, a temperature-field simulation model was constructed based on the moving heat-source principle. This study investigated the influence of spindle rotational speed, abrasive tool feed speed and normal force on the grinding temperature field. The validity of the simulation model was verified through grinding experiments on an Inconel 718 alloy. The experimental results showed a consistent trend in temperature variation between the simulation and actual measurements, with an average deviation of 7.01%. An increase in the spindle rotational speed from 500 to 2500 r/min led to an increase in the grinding temperature from 45.91 to 90.37 °C, indicating a steady upward trend. Conversely, as the abrasive tool feed speed increased from 2 to 10 mm/s, the temperature decreased from 90.37 to 59.02°C. Furthermore, an increase in the normal force resulted in a temperature increase from 50.02°C at 5 N to 90.37°C at 25 N.