Influence of surface functional parameters on friction behavior and elastic–plastic deformation of grinding surface in mixed lubrication state

A new heat transfer model for profile grinding was developed to analyze distortions caused by residual tensile stresses in linear guide rails. The simulative analysis of the thermal effects caused by a non-uniform heat source on the surface using the finite element method depends on an accurate representation of the locally variable contact area. The complexity of the V-groove profile disqualifies a 2-dimensional simulation approches so far used in the literature. This paper focuses on the redefinition of these mathematical relationships of the process parameters and the resulting heat flux. The heat flux model is adapted to the geometry of the workpiece depending on the grinding parameters and approximating the V-groove of a linear guide rail. This 3-dimensional modeling allows a better understanding of the thermo-metallurgical effects that occur during the grinding process. Furthermore, the calculation of the internal stresses induced into the workpiece material through the grinding process is possible. The simulation model results in a generally valid model for the analysis of distortions. In order to confirm the validity of the new heat flux profile, a comparison of the different finite element simulation results was made and experiments under wet grinding conditions were conducted. The results show that the newly developed grinding process model allows a more accurate prediction of workpiece distortion caused by grinding forces and temperatures. This research also offers a new approach to a method based on a 2-dimensional implementation developed in the literature for predicting the distortions of linear guide rails and a derivation of possible simulation-based compensation strategies.

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Characteristics of rolling interface lubrication considering contact surface textures in mixed lubrication

Wang,

Zhang,

Zhang

et al. 2024

Proceedings of the Institution of Mechanical Engineers, Part J:

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This study comprehensively utilizes the mixed lubrication theory and rolling deformation theory to establish a finite element stiffness contact model that considers the surface texture characteristics of the rolling interface. The dynamic explicit finite element analysis is used to obtain the deformed solid, and the turbulent equation is used to control the fluid boundary conditions. The bidirectional Fluid-Structure Interacton (FSI) ansysis is used to study the influence of surface roughness, surface textures, and rolling parameters such as rolling speed on the distribution of oil film pressure and contact characteristics during the rolling process. The results confirm that transverse texture reduces the friction coefficient and dynamic pressure by enhancing the trapping effect of rough peaks and facilitating the entrainment of the fluid film. Under the same textural conditions, the contact area decreases with increasing roughness while the friction coefficient increases. As the rolling speed increases, the rolling pressure decreases to a certain extent, and the contact area ratio will decrease; Lubricants with higher viscosity can effectively reduce the friction and rolling force at the rolling interface. We believe that the insights obtained from the numerical simulations provided in this reaserch will lay a theoretical foundation for subsequent research on plate shape control.

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Influence of surface functional parameters on friction behavior and elastic–plastic deformation of grinding surface in mixed lubrication state

Cited by 3 publications

References 35 publications

Numerical Simulation of Grain Concentration Effect on Output Indicators of Diamond Grinding

Numerical Simulation of Grain Concentration Effect on Output Indicators of Diamond Grinding

3D modeling and simulation of thermal effects during profile grinding

Characteristics of rolling interface lubrication considering contact surface textures in mixed lubrication

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