CFD analysis of multi-layer cooling channels in three-dimensionally structured grinding wheels

Costa, Sharlane; Capela, Paulina; Hassui, Amauri; Ribeiro, J.E.; Pereira, Mário; Soares, Delfim

http://hdl.handle.net/10198/35182

Use this identifier to reference this record.

Name:	Description:	Size:	Format:
CFD analysis of multi-layer cooling channels grinding wheels.pdf		9.24 MB	Adobe PDF	Download

Send Feedback

Authors

Abstract(s)

Minimizing heat damage and surface integrity loss in grinding depends on effective cooling. Conventional techniques, however, suffer with low efficiency because of the fast air barrier restricting fluid access. Grinding wheels with internal cooling channels have been suggested to solve this; nonetheless, the impact of channel geometry and multi-layer topologies is yet unknown. This work investigates their effects on coolant flow pattern and thermal performance by means of computational fluid dynamics (CFD) simulations, experimental validation, and statistical optimization combined. The ideal arrangement was found by the Taguchi- Grey study to be 30 channels, 78 degrees inclination, 1.7 mm diameter and 2 mm interlayer distance. ANOVA determined that diameter (59.7 %) and number of channels (21.8 %) are the most influential parameters. CFD results showed that multilayer structures significantly increase fluid dispersion in the workpiece. The three-layer design stood out for providing the most uniform and dynamic fluid distribution, reducing cooling inconsistencies. Grinding tests confirmed that this configuration achieved the lowest temperatures for all different depths of cut. These findings highlight that increasing the number of flutes alone is insufficient; a three-dimensional flute structure with optimized geometry is essential to ensure efficient cooling. By integrating numerical modeling, statistical optimization, and experimental validation, this study provides a framework for designing grinding wheels with internal cooling channels, improving fluid distribution and thermal control.

Keywords

Taguchi method Grinding performance Grinding CFD Thermal control Fluid distribution Structured grinding wheel

URI

http://hdl.handle.net/10198/35182

Citation

Costa, Sharlane; Capela, Paulina; Hassui, Amauri; Ribeiro, João; Pereira, Mário; Soares, Delfim. (2025). CFD analysis of multi-layer cooling channels in three-dimensionally structured grinding wheels. Applied Thermal Engineering. ISSN 1359-4311. 279, p. 1-12