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

2025Artigo científico Acesso aberto
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datacite.subject.fosEngenharia e Tecnologia::Engenharia Mecânica
datacite.subject.fosEngenharia e Tecnologia::Engenharia dos Materiais
datacite.subject.sdg09:Indústria, Inovação e Infraestruturas
datacite.subject.sdg12:Produção e Consumo Sustentáveis
dc.contributor.authorCosta, Sharlane
dc.contributor.authorCapela, Paulina
dc.contributor.authorHassui, Amauri
dc.contributor.authorRibeiro, J.E.
dc.contributor.authorPereira, Mário
dc.contributor.authorSoares, Delfim
dc.date.accessioned2025-12-05T11:13:54Z
dc.date.available2025-12-05T11:13:54Z
dc.date.issued2025
dc.description.abstractMinimizing 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.eng
dc.description.sponsorshipThis work was supported by FCT national funds, under the national support to R&D units grant, through the reference project UIDB/04436. The authors are grateful to the Foundation for Science and Technology (FCT, Portugal) for financial support through national funds FCT/ MCTES (PIDDAC) to CIMO (UIDB/00690/2020 and UIDP/00690/2020) and SusTEC (LA/P/0007/2020). This work is within the scope of Sharlane Costa Ph.D. degree, in progress, financially supported by the Portuguese Foundation for Science and Technology (FCT) through the Ph.D grant reference 2021.07352.BD.
dc.identifier.citationCosta, 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
dc.identifier.doi10.1016/j.applthermaleng.2025.127633
dc.identifier.issn1359-4311
dc.identifier.urihttp://hdl.handle.net/10198/35182
dc.language.isoeng
dc.peerreviewedyes
dc.publisherElsevier
dc.relationMicroelectromechanical Systems Research Unit
dc.relationMountain Research Center
dc.relationAssociate Laboratory for Sustainability and Tecnology in Mountain Regions
dc.relation.ispartofApplied Thermal Engineering
dc.rights.urihttp://creativecommons.org/licenses/by-nc/4.0/
dc.subjectTaguchi method
dc.subjectGrinding performance
dc.subjectGrinding
dc.subjectCFD
dc.subjectThermal control
dc.subjectFluid distribution
dc.subjectStructured grinding wheel
dc.titleCFD analysis of multi-layer cooling channels in three-dimensionally structured grinding wheelseng
dc.typejournal article
dspace.entity.typePublication
oaire.awardNumberUIDB/04436/2020
oaire.awardNumberUIDP/00690/2020
oaire.awardNumberLA/P/0007/2020
oaire.awardTitleMicroelectromechanical Systems Research Unit
oaire.awardTitleMountain Research Center
oaire.awardTitleAssociate Laboratory for Sustainability and Tecnology in Mountain Regions
oaire.awardURIinfo:eu-repo/grantAgreement/FCT/6817 - DCRRNI ID/UIDB%2F04436%2F2020/PT
oaire.awardURIinfo:eu-repo/grantAgreement/FCT/6817 - DCRRNI ID/UIDP%2F00690%2F2020/PT
oaire.awardURIinfo:eu-repo/grantAgreement/FCT/6817 - DCRRNI ID/LA%2FP%2F0007%2F2020/PT
oaire.citation.titleApplied Thermal Engineering
oaire.citation.volume279
oaire.fundingStream6817 - DCRRNI ID
oaire.fundingStream6817 - DCRRNI ID
oaire.fundingStream6817 - DCRRNI ID
oaire.versionhttp://purl.org/coar/version/c_970fb48d4fbd8a85
person.familyNameCosta
person.familyNameRibeiro
person.givenNameSharlane
person.givenNameJ.E.
person.identifierR-000-6Y8
person.identifier.ciencia-idBE10-34C7-7A2D
person.identifier.ciencia-id0F15-FB62-29DB
person.identifier.orcid0000-0001-6300-148X
person.identifier.ridG-3839-2018
person.identifier.scopus-author-id25638652400
project.funder.identifierhttp://doi.org/10.13039/501100001871
project.funder.identifierhttp://doi.org/10.13039/501100001871
project.funder.identifierhttp://doi.org/10.13039/501100001871
project.funder.nameFundação para a Ciência e a Tecnologia
project.funder.nameFundação para a Ciência e a Tecnologia
project.funder.nameFundação para a Ciência e a Tecnologia
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