Modeling the cooling effect in tool grinding considering process-induced uncertainties

In tool grinding, high local temperatures can lead to geometric deviations, surface layer damage, and residual stresses. The cooling effect of the cutting fluid (CF) is critical but is governed by complex flow and contact conditions. Existing models are either too simplistic or computationally intensive and do not account for stochastic uncertainties such as grain distribution or wetting behavior. As a result, process design remains uncertain, CF usage is often excessive, and energy efficiency is low. This project, in the third funding phase of SPP2231, addresses these challenges by enabling precise prediction of heat dissipation and process reliability.

Objectives

The project aims to develop a multi-scale simulation system for modeling the cooling effect in tool grinding. Models from the micro- and macro-scale are coupled to realistically represent heat and flow fields while maintaining manageable computation times. Material removal is simulated using a grain-resolved grinding wheel model, providing local contact conditions that feed into the thermo-fluid dynamics simulation. This enables calculation of process temperatures under different cooling scenarios. Uncertainties are quantified to allow robust predictions. The results provide guidelines for demand-oriented cutting fluid supply, grinding wheel condition forecasting, and targeted process design with reduced resource consumption.

Benefits

• Process reliability – reduced thermal damage
• Quality – stable tolerances, improved surface finish
• Productivity – more robust design, fewer stoppages
• Sustainability – lower cutting fluid and energy consumption

Approach

We couple grain-resolved material removal, micro-fluid, and thermo-fluid dynamics simulations into a multi-scale model. Experimentally, flow fields, temperature distributions, and process forces during deep-groove grinding are measured and used for validation. The simulation is extended with uncertainty analyses and grinding wheel condition prediction, with the Center for Industrial Mathematics at the University of Bremen performing the thermo-fluid dynamics calculations. The result is a validated methodology for targeted process design and energy-efficient cutting fluid supply.

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Contact Frederik Wiesener via email at wiesener@ifw.uni-hannover.de or by phone at +49 511 762 18238.