Int J Adv Manuf Technol (2006) 31: 268–277
DOI 10.1007/s00170-005-0200-0
ORIGINA L ARTI CLE
Wen Liang Kuo . Jen Fin Lin
General temperature rise solution for a moving plane heat source
problem in surface grinding
Received: 19 July 2004 / Accepted: 13 June 2005 / Published online: 20 January 2006
# Springer-Verlag London Limited 2006
Abstract In the present study, the general solutions for a
transient state as well as for the temperature rise formed
everywhere in the workpiece due to a rectangular-shaped
moving plane heat source arising at the grinding zone are
derived. The present analysis starts from a point heat source
solution by applying the method of separation of variables
to a three-dimensional heat conduction problem. Because
the workpiece moving velocity is quite small, the
convective term related to the workpiece velocity is first
excluded from the heat conduction equation. This work-
piece velocity effect will be included in the model by
slightly modifying the coordinate variable in the sliding
direction shown in the solution of the point heat source.
Therefore, the general three-dimensional solution of the
stationary temperature rise can be expressed in an integral
form as a function of the product value of the unknown
initial condition and the particular solution of temperature
rise. The unknown initial temperature rise in the solution
can be replaced by the point heat source due to frictional
that multiplying the product of the Dirac delta functions
defined for three directions. Using the definition of the
Dirac delta function, the temperature rise solution for a
point heat source can thus be obtained. This solution is
further extended to obtain the moving and uniform heat
sources arising in a rectangular grinding zone. A compar-
ison among the experimental result and the theoretical
results predicted by the present model and Jaeger’s model
[Jaeger JC (1942) Proc Roy Soc, NSW 76:203–224.] show
that the present model is quite accurate and is generally
superior to Jaeger’s model; it can be applied to predict the
three-dimensional temperature rise distributions in the
workpiece.
W. L. Kuo (*) . J. F. Lin
Department of Mechanical Engineering,
National Cheng Kung University,
Tainan, 701, Taiwan
e-mail: z8309007@email.ncku.edu.tw
1 Introduction
In a grinding operation almost all the grinding energy is
converted into heat within a small grinding zone. A large
part of the generated frictional heat flows into the
workpiece, which results in high temperatures at the
interface between the grinding wheel and the workpiece.
Plane heat source problems are frequently encounter in
numerous manufacturing processes such as metal cutting,
grinding, polishing, and spot welding. The thermal analysis
of these applications begins with the solution of a plane
heat source of appropriate shape and frictional heat
generation in the grinding zone. Solutions of plane heat
source problems for either a stationary or moving work-
piece may not be simple and straightforward because they
encounter boundaries where the temperatures are unknown
and only the heat flow rates (or heat fluxes) are known. As
to the technique developments for the solution of the heat
source problem, Jaeger [1] and Carslaw and Jaeger [2]
presented solutions for uniform moving rectangular heat
sources and a uniform stationary heat source using the heat
source method. Trigger and Chao [3] and Chao and Trigger
[4] used Jaeger’s solutions to evaluate the tool-chip
interface temperature in the metal cutting process. In the
field of tribology, similar approximate equations based on
Jaeger’s solution were developed in several studies [5–8]
for a stationary heat source for estimates of the sliding
contact temperature.
Based on Jaeger’s solution of a stationary point heat
source under steady state conditions, the heat source
method has been applied in several studies [9–11] to
develop a solution for a stationary rectangular heat source
whose intensity varies spatially. Several seminal contribu-
tions to the analysis of moving heat source problems had
been made by several authors [1, 12–17], their results
became the basis for much of the applied research that
followed. Because of the mathematical complexity, the
problems were simplified to either a moving point or a
moving line heat source. For the purpose of mathematical

simplicity much of the above analyses were limited to
quasi-steady state conditions. Tian and Kennedy [18] used
Jaeger’s heat source method to develop a series of quasi-
steady solutions for moving heat sources of two types of
heat liberation intensities; the approximate solutions
developed by them are stressed to be close to the exact
solutions. By using the heat source method, Bos and Moes
[19] gave solutions for a moving elliptical heat source with
uniform and semi-ellipsoidal distributions of heat intensity.
In the study of Hou and Komanduri [20], general solutions
in both the transient and steady state for the temperature
rise at any point due to stationary/moving plane heat
sources of different shapes and heat intensity distributions
were presented using Jaeger’s classical heat source method
[1]. This analysis can be used to determine the temperature
distribution not only at the surface but also at all depths
beneath the grinding surface.
One of the most important problems in surface grinding
is how to elucidate the mechanism of the thermal damage.
As for the surface temperatures of the workpiece, most
thermal analyses of grinding processes are based on the
moving heat source theory developed by Jaeger [1]. A
number of attempts have been made by Outwater and Shaw
[21], Des Ruisseaux and Zerkle [22] and Malkin [23] to
solve them analytically. However, many aspects of the
grinding process still remain to be solved because of the
complicated nature of the process.
According to the theories developed in the previous
studies, it is necessary to know the fraction of the total
energy conducted as heat to the workpiece in order to
estimate the workpiece temperature. Some simplified
approaches for estimating the energy partition between
the workpiece and wheel have been proposed for dry and
wet grinding [24–27]. Two studies [28, 29] tried to measure
values of the energy portion using a simple calorimetric
technique. It was shown that the measured values are not
far from the predicted values [25].
A variety of experimental techniques for measuring the
grinding temperature have been applied. One of the most
common methods is the embedded thermocouple [30–33].
This method has been pointed out as flawed because it may
alter the actual heat flow being measured [34, 35].
According to the theoretical analysis for the transient
heat conduction problem of a thermocouple embedded in a
solid body [34], the error in the thermocouple reading
could be as large as 50% of the temperature rise in certain
cases. Infrared radiation measurement techniques have also
been used as a powerful tool for estimating grinding
temperature [36, 37] because of the advantages of high
frequency response and good spatial resolution. However,
the problem of the hole for the sensor drilled in the
workpiece may disturb the temperature distribution in the
workpiece as well. A physically vapor-deposited (PVD)
film method was also applied for the measurement of the
temperature distribution in a cutting tool with satisfactory
accuracy and reproducibility [38, 39]. The PVD film was
used as a thermal sensor, and this method was applied to
measure the temperature in the workpiece during the
surface grinding process.
269
General solutions for the transient state as well as for the
temperature rise everywhere in the workpiece due to
moving plane heat sources of rectangular shape arising at
the grinding zone are derived in the present study. The
present model starts from a point heat source solution by
applying the method of separation of variables to a three-
dimensional heat conduction equation. Due to the small
workpiece moving velocity, the convective term related to
this workpiece velocity is first excluded from the heat
conduction equation. The effect of this workpiece velocity
on the temperature rise will be induced only when the
solution of the point heat source has been achieved. In
order to obtain the temperature rise solution for the point
heat source, the general solution of temperature rise for
each of these three directions can be expressed in an
integral form as a function of the initial condition
(unknown) multiplying the particular solution of the
temperature rise. If the frictional heat Qpt generated as
the point source is known, the three-dimensional initial
condition of temperature rise can thus be replaced by this
point heat source multiplying the product of the Dirac delta
functions defined for all three directions. The temperature
rise solution for the point heat source can thus be obtained
by using the definition of the Direct delta function. This
temperature rise solution for the point heat source is then
further extended to obtain the moving and uniform heat
sources arising in a rectangular grinding zone. This analysis
can be used to determine the three-dimensional temperature
rise solutions of a workpiece in the transient state. The
maximum temperature rises arising at the grinding surface
in different conditions can be predicted by the present
model and Jaeger’s model [1] in order to compare with the
experimental results reported in the literature [29, 39].
2 Temperature rise analyses
A rectangular workpiece with a large thickness undergoing
a grinding process is commonly moving in the x-direction
with a constant sliding velocity νx, which is much lower
than the tangential velocity of the grinding wheel rotating
at a constant angular velocity (see Fig. 1). The temperature
rise (T ¼


ambient , θ: specimen temperature; θambient:
ambient temperature) distribution in the workpiece due to
the generation of the frictional heat arising at the grinding
zone between the grinding wheel and the workpiece
satisfies the following energy equation:
@T @T
Cp
r  ½KrT  þ Cp x ¼ 0; (1)
@t @x
where νx denotes the relative velocity between the
frictional heat source and the moving workpiece, ζ denotes
the workpiece density, Cp denotes the specific heat of
workpiece, and K denotes the thermal conductivity of the
workpiece. In the present study, the frictional heat source is
fixed at a position and νx is actually equal to the velocity of
the moving steel workpiece. This velocity is in practical
270
Fig. 1 Schematic diagram vxτ i vxτ = vx (t – τ i )
of a moving point heat source
τi = 0 τi =τi τi = t
O x,X
Oτi Ot
x y
dτ i
vxt X
z
y y y
vx vx vx

z z z
M

applications a small value. For the convenience of attaining
the analytical solution of T, the convective term Cp x @T
@x is
absent from Eq. 1 first, and the effect of the sliding velocity
(νx) will be included in the later evaluation of the moving
point-source temperature rise solutions in the x-direction.
Therefore, Eq. 1 is now simplified as:
same type of differential equation, their solution has a
similar form, too. By the use of the heat source method
developed by Jaeger and Carslow [2] for the unsteady, one-
dimensional heat transfer, the particular temperature rise
solution Txp for Eq. 4.a arising at various x0
ð
1 < x0 < 1Þ is given as

@T
Cp
r  ½KrT  ¼ 0: (2) 1 0
2=

@t Txp ðx; x0 ; tÞ ¼ 1 e
ðx
x Þ 4 t

; (5)
ð4t Þ =2

If ζ, Cp, and K are assumed to be independent of the where x indicates the position designated to observe the
temperature rise during the grinding process, Eq. 2 is then a temperature rise observation. The general solution of Eq. 4.a
linear differential equation of temperature rise, T(x, y, z, t). is then obtained by integrating Eq. 5 w.r.t x' over
1 < x0
The x-, y- and z- coordinates are shown in Fig. 1. By the < 1 . Then, Tx(x,t) is written as
separation of variables, T(x, y, z, t) can be expressed as:
Z 1
T ðx; y; z; tÞ ¼ Tx ðx; tÞTy ðy; tÞTz ðz; t Þ: (3) 1 0
2=
Tx ðx; t Þ ¼ 1
=2
C ðx0 Þe
ðx
x Þ 4 t
dx 0 ; (6)
ð4tÞ
1
Tx (x,t), Ty (y,t) and Tz (z,t) are the one-dimensional
temperature rise solutions arising in the x-, y- and z- where C(x') denotes an unknown function which is
directions, respectively. By the substitution of Eq. 3 into introduced as the coefficient of the particular temperature
Eq. 2, the three-dimensional energy equation can be rise solution. This unknown function can be determined by
converted into one-dimensional energy equations. They are applying the initial condition of Eq. 4.a.
1
Define  ¼ x
x1 = ; then x0 ¼ x þ ð4t Þ =2 ; and dx0 ¼
0
@2 Tx 1 @Tx
¼ ;
1 < x < 1 (4.a) ð4tÞ 2

@x2  @t 1
=2
ð4t Þ d: Therefore, Eq. 6 can be rewritten as
Z 1   2
1 1
@2 Ty 1 @Ty Tx ðx; t Þ ¼ pffiffiffi C x þ ð4tÞ =2  e
 d: (7)
¼ ;
1 < y < 1 (4.b) 
1
@y2  @t
If fx (x) is now the initial condition, then Tx ðx; t ¼ 0Þ ¼ fx ð xÞ:
This initial condition of temperature rise is presently still an
@2 Tz 1 @Tz unknown. Applying this initial condition to Eq. 7 gives
¼ ;
1 < z < 1; (4.c)
@z2  @t Z
C ð xÞ 1
2
where α is
fx ð xÞ ¼ pffiffiffi e d ¼ C ð xÞerf ð1Þ ¼ C ð xÞ: (8)
the thermal diffusivity of the steel workpiece 
1
K
and,  ¼ Cp : Since these above equations show the
 271

Consequently, Eq. 6 can be rewritten as Equation 9 represents the one-dimensional temperature rise
Z 1 solution in the x-direction. The other two solutions in the y-
1 0 2 and z- directions can be expressed in a form similar to Eq. 9.
Tx ðx; t Þ ¼ 1=
fx ðx0 Þe
ðx
x Þ =4t dx0 : (9)
Then the three-dimensional general solution, according to
ð4tÞ 2
1 the product solution shown in Eq. 3, is written as

Z1 Z1 Z1
1 ðx
x0 Þ2 þðy
y0 Þ2 þðz
z0 Þ2
dx0 dy0 dz0 ;
T ðx; y; z; tÞ ¼ 3
=2
f ðx0 ; y0 ; z0 Þe
4t (10)
ð4t Þ
1
1
1

where f (x', y', z') denotes the initial condition of the three- initial condition of the three-dimensional temperature rise
dimensional temperature rise. This initial condition is can be expressed in relation with Qpt as:
related to the frictional heat produced at the contact point.
At the initial time, the frictional heat (unit: J) is generated Qpt
f ðx0 ; y0 ; z0 Þ ¼ ðx0 Þðy0 Þðz0 Þ: (11)
as the point heat source Qpt. Define δ (unit:m−1) to be Cp
Dirac’s delta function (ðt
aÞ ¼ 1 , if t=a; ðt
aÞ ¼ 0,
otherwise); this function is suitable for the description of Substituting Eq. 11 into Eq. 10 gives
the thermal behavior arising at a contact point. Then the

Qpt Z1 Z1 Z1 ðx
x0 Þ2 þðy
y0 Þ2 þðz
z0 Þ2

T ðx; y; z; t Þ ¼ 3 e
4t  ðx0 Þðy0 Þðz0 Þdx0 dy0 dz0 (12)
ð4tÞ =2 Cp

1
1
1
Qpt x2 þy2 þz2
¼ 3 e
4t :
Cp ð4t Þ =2

Equation 12 is used to express the temperature rise at the the moving coordinate system is now shifted to point Ot. If
point (x, y, z) due to a stationary point heat source, Qpt. the investigation of the temperature rise is made at time t, the
If the point heat source is now moving at a velocity of νx temperature rise arising at an infinitesimal time interval
in the sliding direction of the workpiece, a moving di ð0  i  t Þ due to the liberation rate qpt (unit: J/s) of
coordinate system with its origin located at the moving the point heat source must be evaluated first. Then this
point heat source is helpful for describing the temperature temperature rise at point M is expressed as
rise at the points (x, y, z) and the time t. As Fig. 1 shows, the  
coordinate system with its origin at point O is stationary. As ðx
vx i Þ2 þy2 þz2
qpt di
4t
the point heat source is moved for a time of τi, the moving dT ¼ 3 e : (13)
=2
coordinate system is then shifted by a distance νxτi, and the Cp ð4 Þ
origin is now at point Oi . In Fig. 1, t represents the time
for observation, and the time parameter τ is defined to be By referring to Fig. 1, x
x i ¼x
x ðt
 Þ ¼ ðx
x t Þ þ
(t−τi). As the observation time t is designated, the origin of x  . Since X ¼ x
x t , therefore x
x i ¼ X þ x  . The
272

relationship i ¼ t
 gives dτi=−dτ too. Then, the variable rise solutions arising at the rectangular grinding zone formed
τi in Eq. 13 can now be replaced by τ in the use of the above by the grinding wheel in contact with the workpiece.
two relationships. The temperature rise of point M evaluated If the contact width of the grinding zone is B and the
at the observation time t can thus be obtained by the contact length of the grinding zone is l, the contact area of
integration of Eq. 13 w.r.t τ ranging from 0 to t. Therefore, grinding zone is Bl. Define qo(J/s.) to be the rate of change
of the internal energy, it is related to the heat transfer of
ðX þx  Þ2 þy2 þz2
qpt Rt e
4
frictional heat. Let Qv be the rate of change of the internal
T ðx; y; z; t Þ ¼ 3= ¼0 3= d energy in per unit area of the grinding zone. Therefore,
Cp ð4Þ 2  2
q
2 (14) Qv ¼ o =Bl (unit:J/(s.m2)). For an infinitesimal element
qpt X

2x
R t e
X 2 þy2 þz2  
4

x
e 4
¼ 3= e 0 3= d: dXidyi in the rectangular grinding zone shown in Fig. 2, the
Cp ð4Þ 2  2
qpt parameter in Eq. 15 can be expressed as qpt ¼ Q dXi dyi :
Substituting this expression into Eq. 15 gives
2x 
Define w  4 , Eq. 14 can be rewritten as  
u2
Z 2x t
w
4wi
2
  2  Q dXi dyi x ðX
Xi Þx 4 e
Z xt
w
u
dT ¼ e
(16)
qpt x X 4 e 4w 3
=2
2
3 dw;
T ðx; y; z; t Þ ¼ 3 e
2x
dw; 16K 0 w =2
16K =2
3
0 w =2
(15) fðX
X Þ2 þðy
y Þ2 þðzÞ2 g
1=
2
where ui ¼ i
2
i x
. The integration of
1= Eq. 16 over the entire grinding zone obtains the temper-
ðX 2 þy2 þz2 Þ 2
where u ¼ 2
x
. Equation 15 is used to evaluate ature rise at point M as well as at the observation time t. In
the temperature rise at point M, which is caused by a point the practical applications, only part of the frictional heat is
heat source moving in the x-direction with a velocity of ν x. transferred to the workpiece. If the energy partition
This formula can be further extended to obtain the temperature corresponding to this part is Rw , the temperature rise
solution is thus modified as

2 0   1 3
u2
Z =2 6Z =2 ðX
X Þx B
Z 2
xt
w
4wi
C 7
l B
Rw qo x 6
2i B
4 e
T¼ 3 4 e @ 3 dwC 7
Adyi 5dXi : (17)
16K =2 ðlBÞ
= l

=2
B
0 w =2
2

Equation 17 is derived on the base of an infinite body in surface grinding, the assumption of an infinite body for the
the x-, y- and z- directions. In the practical applications of heat transfers in the x- and y- directions is valid; however,

Fig. 2 Schematic diagram l

of a moving rectangular heat
source

Rectangular grinding zone

B Ot
Xi
yi
dyi

dXi y
Xi
X

yi
z
vx

zi M
 273

it is invalid in the z-direction. Since the heat transfer of value obtained by the assumption of infinite body. There-
workpiece in the z-direction occurs only in a semi-infinite fore, Eq. 17 is modified as:
body, the qo value in Eq. 17 is theoretically double the

2 0   1 3
u2
Z =2 6Z =2 Z 2
xt
w
4wi
ðX
Xi Þx B C 7
l B
Rw qo x 6 B
4 e
T¼ 3 4 e
2
@ 3 dwC 7
Adyi 5dXi : (18)
8K =2 ðlBÞ
=2
l

B=2 0 w =2

Equation 18 is applied to obtain the temperature rise the workpiece length in the grinding direction. The max-
distribution on the grinding surface for a moving surface imum temperature rise corresponding to the left profile is
heat source. 484 K, which is the lowest of these three profiles. As the
grinding zone is shifted to the position in the middle of the
grinding length, the maximum temperature rise is elevated
3 Results and discussion to 535 K. If the grinding zone is further moved to the
position nearby the right edge (the trailing edge) of the
Figure 3 shows the temperature rise solutions evaluated at workpiece, the peak temperature rise remains at 535 K.
three positions of the grinding zone. The operating con- Each of these three temperature rise profiles shows that the
ditions of grinding are given as the same as that shown in maximum temperature rise is generally not generated
the study of Kato and Fujii [29]. They are given in Table 1. exactly in the middle of the grinding zone, but is slightly
The steel workpiece used in this study shows the dimen- shifted leftward. After the maximum temperature rise is
sions of length × width × thickness as 50×10×50 mm. The reached, these profile always show a sharp decrease in
left temperature rise profile is obtained for the left edge of temperature rise nearby the front side (the right edge) of the
the grinding zone exactly located at the left edge of the grinding zone. In the use of the present model for the
workpiece; whereas the right temperature profile, which is evaluations of the temperature rise, there exists a singular
shown for the right edge of the grinding zone, is exactly point at w=0 in the integration expression of Eq. 18.
located at the right edge of the workpiece. The temperature Therefore, a proper choice of a nonzero value of w is needed
rise profile in the middle, which is attained for the central to solve this problem. Several very small values have been
line of the grinding zone, is exactly located in the middle of tried as the low bound of the integration. It is interesting that
the choice of the low-bound value is of importance to the
600 smoothness of the temperature rise profile shown in the
region near its peak value. As Fig. 4 shows, zigzags are
ΤM = 535 K
ΤM = 484 K present at the curves if a relatively small value is chosen as
ΤM : Maximum the low bound. As the low-bound value is elevated to 10−4,
temperature rise
Grinding conditions: Table B the curve becomes smooth but the peak value is not
Grinding wheel: WA46J7V profoundly affected by the choice of this value. Therefore,
400 Workpiece: JIS S55C steel 10−4 is thus chosen as the low bound in the present study.
Temperature Rise (K)

The temperature rise solutions predicted by the present

model are exhibited for comparison with that obtained
from the measurements of the workpiece temperature rises
at different depths beneath the grinding surface. In Fig. 5,
the solid curve shows the theoretical solutions of the
200 temperature rises evaluated at various depths; whereas the
dash curve shows the experimental data given in the study
Table 1 Grinding conditions [29]
Wheel diameter Ds 200 mm
Depth of cutting ae 20 μm
0
Workpiece dimension (length × 50×10×50 mm
0 10 20 30 40 50 width × thickness)
Workpiece Length (mm)
Wheel velocity Vs 30 m/s
Workpiece moving velocity VW 0.05 m/s
Fig. 3 Temperature rise profile for the grinding zone located at the Grinding method One – pass, up grinding,
two ends and in the middle of the workpiece. They are obtained at dry condition
the plane of y=0
274
540 2 600
3 Depth Max. Position of max.
temp. rise temp. rise
530 • 0 µm 535 K 24.2 mm
Maximum Temperature Rise (K)

1 -200 µm 406 K 24.2 mm

-400 µm 309 K 24.0 mm
-600 µm

Temperature Rise (K)

400 ° 240 K 23.6 mm
520 -800 µm 193 K 23.2 mm

Low bound of integration Grinding Conditions : See Table 1

510 Grinding Wheel : WA46J7V
1 10 -4 Workpiece Material : JIS S55C steel
2 10 -5 200
500 3 10 -6

490
0 0.1 0.2 0.3 0.4 0.5 0
Distance from the Left Edge of Grinding Zone (mm)
0 10 20 30
Fig. 4 Local temperature rise profiles for the grinding zone located Distance from Workpiece Leading Edge (mm)
in the middle of the workpiece as well as at the plane of y=0. They
show the part of the entire profile in the grinding zone in order to Fig. 6 Temperature rise profile for the grinding zone located in the
show the effect of the low bound of an integration on the profile middle of the workpiece as well as at the plane of y=0. They are
smoothness evaluated at different depths beneath the grinding surface

of Kato and Fujii [29]. These theoretical solutions and
experimental results are presented for the central line of the
grinding zone located just in the middle of the grinding
length. Both the theoretical solutions and the experimental
results show a nonlinear decline when the depth is
increased. The closeness of the theoretical solutions to
the experimental results indicates that the theoretical
solutions predicted by the present temperature rise model
are reliably accurate. By the present model, the three-
dimensional temperature rise distributions in the workpiece
can be obtained for the grinding zone in everywhere of the
workpiece surface. Figure 6 shows the temperature rise
1000
900
800
Maximum Temperature Rise (K)
Grinding Conditions : See Table 1
profiles for the grinding zone just in the middle of the
grinding length as well as at different depths beneath the
workpiece surface. Significant differences of temperature
rise arising at different depths are primarily present at the
grinding zone, these differences among different depths are
narrowed to be negligibly small as the workpiece surface is
sufficiently far from the grinding zone.
The moving velocity of a workpiece becomes one of the
influential factors in the temperature rise distributions in
the workpiece. In order to solve the temperature rise
solutions arising at different operating conditions or
different workpiece or grinding wheel material, the energy
partition of the total frictional heat associated with the
workpiece must be first determined by thermal experi-
ments. In the present study, the theoretical results predicted
by the present model are obtained in the use of the same

700 Grinding wheel : WA46J7V conditions and energy partition as given in the experiments
600 Workpiece : JIS S55Csteel reported in the literature [39]. They are given in Table 2.
500 Figure 7 shows the theoretical and experimental results of
400 the temperature rises evaluated at different depths beneath
the grinding surface, the solid curves are the theoretical
300

Table 2 Grinding conditions [39]

200
experimental results [29] Grinding wheel WA46J7V
theoretical results Workpiece material JIS S55C steel
Wheel diameter Ds 240 mm
Depth of cutting ae 20 μm
100
Workpiece dimension (length × 50×10×50 mm
0 200 400 600 width × thickness)
Depth Beneath Workpiece Grinding Surface (µm)
Wheel velocity Vs 27.5 m/s
Fig. 5 Maximum temperature rises for the profiles evaluated at Workpiece moving velocity VW 0.025 m/s, 0.2 m/s
different depths beneath the grinding surface. These profiles are Grinding method One – pass, up grinding,
obtained for the grinding zone located in the middle of the dry condition
workpiece as well as at the plane of y=0
 275

600 Grinding Conditions : See Table 2

VW = 0.025 m/s
(theoretical results)
500 (experimental results)[39]
Maximum Temperature Rise (K)

VW = 0.2 m/s
400 (theoretical results)
(experimental results)[39]

300

200

100

0
0 200 400 600 800 1000
Depth beneath the Grinding Surface (µm)
Fig. 8 Comparisons of the experimental and theoretical results of
Fig. 7 Comparisons of the experimental and theoretical results of
the maximum temperature rises arising at the surface grindings in
the maximum temperature rises evaluated at different depths beneath the use of four workpiece materials. These results were obtained for
the grinding surface as well as at two workpiece materials moving
the grinding zone located in the middle of the workpiece as well as
obtained for the grinding zone located in the middle of the at the plane of y=0
workpiece as well as at the plane of y=0
results predicted by the present model for two different reported in the study of Kato and Fujii [29]. They are
workpiece moving velocities. The hollow circles or squares adopted here to compare with that predicted by the present
denote the experimental results shown in the study of Kato model and the theoretical model developed by Jaeger [1].
and Fujii [39]. Comparisons of the theoretical and The thermal properties of these four materials are given in
experimental results show that the difference between Table 3. Figure 8 shows that the error between the
them is quite small, irrespective of the workpiece moving experimental result and the theoretical result predicted by
velocity. These differences are always in the range less than the present model is quite small, it is in the range of 2.2%
4%. In addition to the validity of the present model, the (stainless steel) to 8.0% (cast iron). The difference between
temperature rise solutions on the grinding surface, includ- the experiment result and the theoretical result predicted by
ing the grinding zone, can be predicted; whereas they are the model developed by Jaeger is mostly larger; it is in the
unable to be achieved through their thermal experiments. range of 1.3% (stainless steel) to 15.9% (cast iron). It can
The theoretical results indicated that the maximum tem- thus be concluded that the accuracy of the theoretical
perature rise arising at the grinding surface as well as at a solution predicted by the present model is superior to that
workpiece sliding velocity of 0.2 m/s is slightly higher than of the Jaeger’s model. The material of the grinding wheel,
that at a sliding velocity of 0.025 m/s. However, the as the experimental results have shown in the study of Kato
temperature rise behavior exhibited at a sufficiently large and Fujii [29], is also of importance to the maximum
depth beneath the grinding surface is exactly opposite to temperature rise solution. The thermal properties of four
that shown at the grinding surface. This characteristic is grinding wheel materials are given in Table 4. The
attributable to the factor that the time for the response of experimental and theoretical results are both shown in
frictional heat at a depth is relatively shorter as compared Fig. 9 for four kinds of grinding wheel materials. The error
with the case of having a larger workpiece sliding velocity. in the temperature rise formed between the experimental
The workpiece material is certainly one influential factor result and the present theoretical result is in the range of
in the maximum temperature rise. The experimental results 0.1% (silicon carbide) to 6.8% (diamond); whereas the
of the maximum temperature rise obtained from the surface error formed between the experimental result and the
grindings of four kinds of workpiece materials have been
Table 4 Physical properties of grinding wheel material [29]
Grinding wheel Symbol ρ C k α
Table 3 Physical properties of workpiece material [29]
kg/m3 J/(kgK) w/(mK) m2/s
Workpiece Symbol ρ kg/m3 C J/(kg K) k w/(m K) α m2/s
Aluminum WA46J7V 3800 712 16.7 6.17×10−6
−6
Carbon steel S55C 7860 490 44.2 11.5×10 oxide
Stainless steel SUS304 7920 499 16.0 4.05×10−6 Silicon carbide GC46J7V 3200 628 92.1 45.8×10−6
Brass C2801 8390 375 123 39.1×10−6 Boron nitride CB80M100V 3480 506 481 273×10−6
Cast iron FC20 7320 503 42.8 11.6×10−6 Diamond SD270N75V 3520 507 900 504×10−6
276
Fig. 9 Comparisons of the experimental and theoretical results of
the maximum temperature rises arising at the surface grindings in
the use of four grinding wheel materials. These results were obtained
for the grinding zone located in the middle of the workpiece as well
as at the plane of y=0
Jaeger’s model is in the range of 1.3% (diamond) to 12.1%
(cubic boron nitride). The maximum temperature rise
corresponding to the diamond grinding wheel is the lowest
of the four grinding wheel materials. The interpretation of
this lowest value can be attributed to the smallest frictional
heat and energy partition (Rw) when using the diamond
grinding wheel. The grinding wheel material with a high
thermal conductivity is, in general, helpful for the lowering
of the temperature rise in the grinding zone, too. Figure 10
shows the temperature rise solutions evaluated at three
cutting depths (5, 10, and 20 μm), the tangential forces
corresponding to these three cutting depths have been
400
Grinding Conditions : See Table 5
300 Depth of
Temperature Rise (K)
Grinding
20 µm
10 µm
200 5 µm
100
0
0 20 40
Distance from Workpiece Leading Edge (mm)
Fig. 10 Temperature rise profile for the grinding zone located in the
middle of the workpiece as well as at the plane of y=0. They are
evaluated at different cutting depths
Table 5 Grinding conditions [40]
Grinding wheel WA100N8V
Workpiece material JIS S50C steel
Wheel diameter Ds 205 mm
Depth of cutting ae 5 μm, 10 μm, 20 μm
Workpiece dimension (length × 100×10×1.5 mm
width × thickness)
Wheel velocity Vs 30 m/s
Workpiece moving velocity VW 0.08 m/s
Grinding method One – pass, dry condition
measured to be 1.1, 2.0, and 3.6 N/mm, respectively [40].
The grinding conditions are given in Table 5. The
analytical solutions show that the temperature rise is raised
by increasing the cutting depth. The peak values of the
temperature rise present a nonlinear increase when in-
creasing the cutting depth. However the validity of these
solutions can not be confirmed from the details provided in
the study of Matsuo et al. [40].
4 Conclusions
1. The temperature rise solutions predicted by the present
model show quite small errors as compared with the
reported experimental results. This model can be
applied to predict the three-dimensional temperature
rise distributions in the workpiece accurately irrespec-
tive of the position of the grinding zone.
2. The maximum temperature rise always forms in the
grinding zone located nearby the middle of the workpiece
length in the sliding direction. It is dependent upon the
workpiece sliding velocity, the grinding wheel material,
the workpiece material, and the cutting depth in practical
applications. For workpieces with the same material, the
increase in the workpiece sliding velocity can generate a
relatively high temperature rise on the grinding surface.
However, the difference in the maximum temperature due
to the change in the workpiece moving velocity is quite
small. The increase in the workpiece velocity would cause
a relatively low workpiece temperature rise formed at a
sufficiently large distance beneath the grinding surface.
The effect of the grinding wheel and workpiece materials
on the workpiece temperature rise becomes more com-
plicated. The temperature rises of a workpiece are simul-
taneously dependent upon several influential factors.
Nevertheless, the increase in the thermal conductivity of
the workpiece is helpful for reducing the maximum tem-
perature rise in the grinding zone. Increasing in the cutting
depth of the workpiece would bring in the elevation of the
maximum temperature rise in a nonlinear form.
60
5 Notation
α Thermal diffusivity of specimen
B Contact width of the grinding zone

Cp Heat capacity at constant pressure
Ds Wheel diameter
K Thermal conductivity of workpiece
l Contact length of the grinding zone
Qpt,, qpt The point heat source; the liberation rate of the
point heat source
q0, Qv The rate of change of the internal energy; The
rate of change of the internal energy per unit
area of the grinding zone
θ, θambient Specimen temperature; ambient temperature
Rw Partition of total grinding energy entering
workpiece
T Temperature rise at any point M at any time
Vs,Vw,vx, Wheel peripheral velocity; workpiece velo-
city; the velocity of the moving heat source
along x direction
ξ Workpiece density
τ The time after the initiation of an instanta-
neous heat source
t Time of observation or the time after the
initiation of a continuous heat source
xi, yi Coordinates of a rectangular plane heat source
x, y, z Coordinates of the point M where the temper-
ature rise is concerned
Xi, yi Coordinates of a rectangular plane heat source
in a moving coordinate system
X, y, z Coordinates of the point M where the temper-
ature rise is concerned , in a moving coor-
dinate system
δ Dirac’s delta function(ðt
aÞ ¼ 1 , if t=a;
ðt
aÞ ¼ 0, otherwise)
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