Modulation of Airflow Field in Grinding Zone with Helical-grooved Structured Grinding Wheel and Optimization of Grinding Performance

XU Xiaoyu; CHEN Yi; ZHUO Xin; BI Guo; LI Maoyuan; WANG Zhenzhong

doi:10.3969/j.issn.1674-6457.2025.11.009

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (11) : 105-115. DOI: 10.3969/j.issn.1674-6457.2025.11.009

Intelligent Processing of Advanced Materials

Modulation of Airflow Field in Grinding Zone with Helical-grooved Structured Grinding Wheel and Optimization of Grinding Performance

XU Xiaoyu, CHEN Yi, ZHUO Xin, BI Guo, LI Maoyuan^*, WANG Zhenzhong^*

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Abstract

During the grinding of hard and brittle optical components with grinding wheels, the high-speed rotation forms an air barrier layer that prevents the grinding fluid from penetrating into the grinding zone, resulting in insufficient cooling and poor lubrication. The work aims to address this issue by investigating the influence of a textured grinding wheel on the airflow field in the grinding zone, optimizing the surface structure of the grinding wheel to improve the utilization of grinding fluid, thereby reducing the grinding force and temperature. Computational fluid dynamics (CFD) simulations and grinding experiments were combined to establish three-dimensional models of conventional grinding wheels and structured grinding wheels with straight grooves, helical grooves, and V-shaped grooves to simulate the airflow field distribution. Based on the simulation results, a bronze-bond diamond helical-grooved grinding wheel was fabricated and tested on a grinding machine using fused quartz workpieces. The simulation results of the airflow field showed that the sum of the absolute values of the positive and negative peak pressure on the surface of the workpiece of the helical-grooved structured grinding wheel was the smallest. The grinding test results indicated that the helical-grooved grinding wheel effectively reduced both the grinding force and temperature. Within a rotational speed range of 500-2 000 r/min, the normal grinding force decreased by 28.7%-41.5%, and the grinding temperature dropped by 8%-20.2%. Similarly, under a grinding depth range of 100-400 μm, the normal grinding force was reduced by 33.6%-40.9%, while the grinding temperature decreased by 17.2%-19.3%. The helical-grooved structured grinding wheel effectively weakens the air barrier and eliminates noticeable return flow at the grinding zone inlet. It significantly improves grinding fluid utilization and enhances the grinding performance of fused quartz components. This study provides a new solution for low-damage machining of optical elements.

Key words

structured grinding wheel / airflow field / grinding / numerical simulation / optical processing

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XU Xiaoyu, CHEN Yi, ZHUO Xin, BI Guo, LI Maoyuan, WANG Zhenzhong. Modulation of Airflow Field in Grinding Zone with Helical-grooved Structured Grinding Wheel and Optimization of Grinding Performance[J]. Journal of Netshape Forming Engineering. 2025, 17(11): 105-115 https://doi.org/10.3969/j.issn.1674-6457.2025.11.009

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