Coolant condition and spindle power in high-efficiency-deep-grinding of nickel-based superalloy profile part

Coolants play an important role in controlling thermal damage in high-efficiency deep grinding (HEDG). The cooling condition in the grinding contact zone (GCZ) determines the cooling effect during the grinding process. Furthermore, when profile grinding is performed, owing to the complexity of the shape, the cooling effect varies at different positions. Therefore, in this study, a device that includes a pressure sensor and semi-natural thermocouples was introduced to evaluate the cooling conditions in the GCZ during HEDG. Thereafter, the influences of the grinding parameters and outlet velocity of the coolant on the pressure distribution were investigated. The grinding speed and outlet velocity of the coolant have significant impacts on the cooling condition, whereas the influences of the infeed speed and depth of cut are limited. The coolant pressure distributions during the profile grinding were measured, analyzed, and optimized. The needle-shaped nozzle, which adapts to the profile, has a better cooling effect than the shoe-shaped nozzle. Moreover, the influence of the coolant delivery on the spindle power was discussed. The outlet velocity of the coolant jet and grinding speed have significant effects on the idle and grinding powers. Therefore, it is recommended to consider the influence of grinding speed during HEDG.