3D modeling and simulation of thermal effects during profile grinding

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.