Inverse Heat Transfer Analysis of Grinding, Part 1: Methods

Abstract

Thermal analyses of the grinding process generally require assumptions concerning the distributions of the heat flux to the workpiece within the grinding zone and convective cooling outside the grinding zone. The present work is concerned with the use of inverse heat transfer methods to estimate the heat flux and convection heat transfer coefficient distributions on the workpiece surface during straight surface grinding from temperature measurements within the workpiece. In the present paper, three inverse heat transfer methods are developed: temperature matching, integral, and sequential methods. Each method is evaluated for accuracy and stability using simulated temperature data. The selection of the sampling frequency of the temperature measurements and location of the temperature sensor are found to be critical for both estimation accuracy and stability. In a second paper, these inverse heat transfer methods are applied to estimate the distributions of the heat flux and convection heat transfer coefficients on the workpiece surface for grinding of steels with aluminum oxide and CBN abrasive wheels.