MODELLING AND EXPERIMENTAL RESEARCH OF THE HEAT TRANSFER PROCESSES WHILE GRINDING WORKPIECES WITH PLASMA COATINGS
Keywords:temperature field, modelling, heat transfer, grinding, plasma coatings, energy distribution.
AbstractIn the process of grinding, high values of thermal energy are generated due to the friction and stresses that occur when an abrasive grain removes the material of the surface layer. The major part of the produced energy flows into the workpiece that may have a negative impact on serviceability of the processed tool. Therefore productivity, quality and cost of the technological process of plasma coatings grinding depends on distribution of thermal energy, since an excessive increase of temperature within the contact zone between the grinding wheel and the workpiece causes surface and structural defects generation and propagation. Results of modelling of the temperature thermal field of plasma coatings during the grinding process are considered in the presented research. The obtained experimental data confirms estimated results on temperatures produced while the workpieces are being processed. Experimental testings are carried out for different conditions of dry and lubricated friction to define maximum values of temperatures for grinding regimes with the use of the cutting fluid. Analysis of the temperature field profile is required to obtain information about the heat energy distribution within a grinding zone, occurring heat transfer processes and energy fraction transported to the workpiece with a coating layer. This data is especially important in order to reduce grinding defects such as grinding burns and cracks, structural changes of plasma coating material and other intrinsic defects propagation as they tend to become centers of the possible crack formation. Another common type of defects, that makes it inappropriate to use a workpiece after being processed, is debonding of a coating layer from a substrate. In order to avoid the destruction of adhesive contacts between the coating layer and the substrate and to provide the required quality of the processed surface, modelling of temperature field and heat transfer distribution is necessary while setting optimal conditions for grinding plasma coatings.
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