Computational investigation for structural behavior in deep grinding process

This paper includes the computational analysis of the deep grinding process for various parameters. The fluid–solid interaction modeling has been done using ANSYS software. Firstly, CFD analysis was done to analyze the maximum grinding temperature. Then, this CFD model was coupled with a structural model to evaluate the grinding zone’s maximum equivalent stresses, shear stress, and thermal strain. Such simulation work for any manufacturing process reduces the number of experiments performed, saving the cost and time for any manufacturing process. The model used in this study was validated with previous results for maximum change in temperature, and a 1% deviation was recorded in both results. The maximum temperature in the grinding zone increases with an increase in depth of cut, and maximum temperatures of 370 and 619 K were found for water and kerosene at a depth of cut 1.1 and wheel velocity of 60 m/s, respectively. The stresses and thermal strain increase with increased depth of cut while decreasing with an increase in wheel velocity. A lower value of equivalent stress, shear stress, and thermal strain was observed in the case of water as a coolant than the kerosene oil. The maximum equivalent stress, shear stress, and thermal strain 456 MPa, 207 MPa, and 0.00783 are observed at 1.1-mm depth of cut for kerosene oil at 60 m/s wheel velocity, respectively. The stresses and thermal strain increase with maximum grinding temperature.