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<p>Polycrystalline diamond (PCD) is a common material for cutting tools which, due to its high hardness, is frequently machined through grinding processes. The type of cooling lubricant used for grinding PCD strongly influences the tribological conditions and thus the thermo-mechanical load in the contact between the diamond grinding wheel and the ground material. A systematical investigation of the material removal mechanisms in the grinding of PCD with a water-based cooling lubricant has not yet been published but would be necessary for a knowledge-based process design. In this work, a contribution to the state of the art is made through an investigation of the microscopic thermal loads in the contact zone as a function of the water-based cooling lubricant concentration by means of a finite element (FE) simulation. The simulation results were validated through experimental grinding tests. It was shown that the grinding of PCD with a water-based cooling lubricant is leading to temperatures below 90&#xa0;°C on both the PCD workpiece and the grinding wheel side. Therefore, it is assumed that this grinding process is mainly based on mechanical rather than thermal load. In the future, the knowledge gained from the simulations will be implemented in an explanatory model for the material removal mechanisms, as well as grinding wheel wear mechanisms during PCD grinding with water-based cooling lubricants as a function of the thermo-mechanical loads. Therefore, the results of this study serve as a foundation for the knowledge-based development of suitable grinding strategies for PCD cutting tools.</p>

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Thermal analysis of the polycrystalline diamond grinding process with a water-based cooling lubricant by numerical simulation

  • 期刊论文

  • 发表日期：

    2025年1月6日

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  • Peter Breuer,
  • Mick Gilles,
  • Jan Knothe,
  • Sebastian Prinz,
  • Thomas Bergs

摘要

Polycrystalline diamond (PCD) is a common material for cutting tools which, due to its high hardness, is frequently machined through grinding processes. The type of cooling lubricant used for grinding PCD strongly influences the tribological conditions and thus the thermo-mechanical load in the contact between the diamond grinding wheel and the ground material. A systematical investigation of the material removal mechanisms in the grinding of PCD with a water-based cooling lubricant has not yet been published but would be necessary for a knowledge-based process design. In this work, a contribution to the state of the art is made through an investigation of the microscopic thermal loads in the contact zone as a function of the water-based cooling lubricant concentration by means of a finite element (FE) simulation. The simulation results were validated through experimental grinding tests. It was shown that the grinding of PCD with a water-based cooling lubricant is leading to temperatures below 90 °C on both the PCD workpiece and the grinding wheel side. Therefore, it is assumed that this grinding process is mainly based on mechanical rather than thermal load. In the future, the knowledge gained from the simulations will be implemented in an explanatory model for the material removal mechanisms, as well as grinding wheel wear mechanisms during PCD grinding with water-based cooling lubricants as a function of the thermo-mechanical loads. Therefore, the results of this study serve as a foundation for the knowledge-based development of suitable grinding strategies for PCD cutting tools.