Coolant flow in structured grinding wheels: CFD validation via high-speed imaging and particle tracking

Le résumé fourni par la source

• • CFD validated by particle tracking with ≤16 % deviation in velocities. • • High-speed imaging confirmed jet coherence predicted by CFD simulations. • • Channel inclination dictated jet velocity, direction, and flow stability. • • Positive oriented channels reduced grinding temperature by up to 67 %. • • CFD–experiment approach advances thermal management in machining operations. Efficient coolant delivery is essential in grinding to control heat generation, minimize tool wear, and preserve workpiece integrity. However, computational fluid dynamics (CFD) models commonly used for coolant system design remain rarely validated due to the extreme speeds and complex multiphase flows involved. This work addresses this gap by combining CFD simulations with targeted experiments to evaluate heat removal effectiveness in internally cooled grinding wheels with three channel inclinations: positive, straight, and negative. Transparent resin prototypes enabled high-speed imaging and particle tracking for flow field validation, while grinding tests measured temperature rise and mechanical loads. Results demonstrate that channel inclination strongly affects fluid acceleration, jet coherence, and penetration into the grinding zone, with the positive inclination producing the highest outlet velocities and reducing temperature rise by up to 67%. Particle tracking confirmed CFD predictions within 16% deviation, validating the model’s reliability. By establishing a direct correlation between coolant jet dynamics, heat dissipation, and process performance, this study demonstrates a methodology for the thermal optimization of internal cooling systems in rotating tools. The approach provides a pathway for improving energy efficiency, extending tool life, and reducing coolant consumption in industrial machining processes.

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