Research Progress on the Characteristics and Regulation Technique of Gas-liquid Flow Field in Grinding Zone of Grinding Wheel

doi:10.3901/JME.260701

Abstract

Abstract: As a key process in the field of precision manufacturing, grinding has long faced the bottleneck of high grinding temperatures that easily induce thermal damage to workpieces. Due to the constraints of the gas barrier effect, the traditional cooling process can only achieve an effective utilization rate of 20%～40% of the coolant, resulting in the dual dilemma of high consumption, low efficiency and environmental pollution. The basic principles and research progress of the flow field in the contact area between the grinding wheel and the workpiece are systematically sorted out, and the latest breakthroughs in the three types of active flow field control strategies, namely, supply device design, structured grinding wheel design, and grinding process optimization, are discussed in detail. Compared with conventional nozzles, solid nozzles or 3D printing nozzles can increase material removal rates by nearly 30% and reduce coolant consumption by about 70%. Through the flow-guiding structure and the centrifugal force-pressure difference coupling mechanism, the structured grinding wheel can increase the effective flow rate in the grinding area by nearly 3 times and reduce the grinding temperature by up to 50 ℃. Compared with pure pneumatic atomization technology, pneumatic-electrostatic synergistic atomization technology can reduce the emission concentrations of PM10 and PM2.5 particles by approximately 80% and 90% respectively. It is pointed out that the current research urgently needs to break through the two bottlenecks of insufficient modeling accuracy of gas-liquid-heat multi-physics field coupling and lack of micro-nanoscale lubrication mechanism under extreme working conditions. Future research should focus on breaking through the theory of coordinated control of multiple physical fields, focusing on the study of gas-liquid interface dynamics under the action of magnetic field, electric field and ultrasonic composite field, innovatively developing an intelligent grinding optimization system integrating digital twins and deep learning, building a dynamic flow field control system for extreme manufacturing conditions, and developing cross-scale thermal-mechanical coupling energy recovery technology, so as to promote the evolution of precision grinding towards an ultra-low consumption, ultra-high efficiency and zero emission manufacturing paradigm.

Key words: grinding, air barrier effect, gas-liquid flow field, flow field regulation, lubrication, cooling

CLC Number:

TG580

DENG Hui, WANG Qian, DENG Zhaohui, YI Jun. Research Progress on the Characteristics and Regulation Technique of Gas-liquid Flow Field in Grinding Zone of Grinding Wheel[J]. Journal of Mechanical Engineering, 2026, 62(13): 363-385.

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