S.

Chandrasekar
School of Industrial Engineering.
T. N. Farris
School of Aeronautics and Astronautics.
Purdue University,
West Lafayette, IN 47907
B. Bhushan
IBM Research Division,
Almaden Research Center,
San Jose, CA 95120-6099
Grinding Temperatures for
Magnetic Ceramics and Steel
Grinding temperatures are measured using an infrared sensor in ferrite and steel.
For reference purposes, temperatures are also measured in a reduced model for
grinding which consists of a single diamond grain sliding across the workpiece sur-
face at high speed. The results include temperature as a function of sliding velocity,
rate of temperature decay as the grain moves away from contact, and histograms of
the frequency that grains on the grinding wheel attain a given temperature. It is
found that temperature measurements can be used to detect out-of-roundness in the
wheel. Finally, a simplified two-dimensional model based on a heat flux moving
with constant velocity gives reasonably good agreement with experiment.

1 Introduction
Nickel-zinc and Manganese-zinc ferrites are widely used as
recording head materials in magnetic storage systems. This ap-
plication requires extremely good control of the geometry,
surface finish, and integrity (residual stress, cracking, and
alteration of surface structure and chemistry) of the fin-
ished surface. Diamond grinding is an important manufactur-
ing process used in the finishing of these ceramics. The grind-
ing process has a significant influence on the quality of the
finished work surface.
High temperatures are produced at the wheel-work interface
and in the workpiece subsurface during grinding (Shaw, 1984b
and Malkin, 1984). The high temperatures and the plastic
deformation/brittle fracture induced by the grinding process
introduce various forms of damage such as microcracking,
residual stress, and phase transformations in these ceramics
(Marshall et al., 1983, Green et al., 1983, and Chandrasekar et
al., 1987). This damage in turn alters the mechanical,
magnetic, and electronic properties of the ceramics. Addi-
tionally, in magnetic ceramics, localized heating above the
Curie temperature can sometimes cause undesirable changes in
magnetic properties. Some of these aspects are discussed by
Snelling (1969), Stokes (1972), and Chandrasekar et al (1986,
1987). Furthermore, the high temperatures existing at the
abrasive grain tip during grinding are an important cause of
grinding wheel wear (Malkin, 1984). Examples in this regard
are the diffusion wear of diamond while grinding ferrous
metals (Komanduri and Shaw, 1974) and the graphitization of
diamond above 850°C (Field, 1982). Thus, it has long been
recognized that thermal phenomena play a key role in the
mechanics of grinding. Therefore, abrasive grain tip and
workpiece temperatures are of fundamental interest and a
critical need exists to measure them accurately. Such
measurements would enable a quantitative understanding of
the factors influencing the grinding temperature distribution
Contributed by the Tribology Division of THE AMERICAN SOCIETY OF
MECHANICAL ENGINEERS and presented at the STLE/ASME Joint Tribology
Conference, Fort Lauderdale, Fla., October 16-19, 1989. Manuscript received
by the Tribology Division March 17, 1989. Paper No. 89-Trib-57.
in magnetic ceramics and, consequently, the development of
better control of the grinding process for recording head
manufacture.
Abrasive grains in diamond/CBN grinding wheels are
typically 20 microns to 100 microns in diameter (Chan-
drasekar et al., 1987) and peak abrasive grain tip temperatures
exist over a very small area. Also, since the grinding wheel
rotates with high peripheral velocities (approximately 30 m/s),
a sensor is only able to observe the abrasive grain for times of
the order of 20 microseconds. Therefore, a detector for grain
tip temperature measurements must have the following
characteristics:
(a) The ability to focus on small and variable areas (ap-
proximately 30 microns in diameter).
(b) A rapid response time (10 microseconds or less).
(c) It must be of the noncontact type and sensitive to
temperatures over a wide range.
Outwater and Shaw (1952), Sato (1954), Littmann and
Wulff (1955), and Malkin and Anderson (1974) measured
grinding temperature using a variety of thermocouple techni-
ques. These studies reported temperatures ranging from
200-800°C while grinding steels. Snoeys et al (1978) reviewed
these studies in great detail. The thermocouple probes have a
poor frequency response and spatial resolution; hence these
measurements lack accuracy (Peters, 1983).
Mayer and Shaw (1956) were the first to obtain the
temperature of a freshly ground steel surface by measuring the
infrared radiation emitted from it. Qualitative study of the in-
frared radiation emitted by the wheel and chips were made by
Kops and Shaw (1983) to investigate the grinding mechanism.
Chandrasekar et al., (1987) and Ueda et al., (1985) have
recently reported results of preliminary investigations of
metal-grinding temperatures using infrared sensors. Infrared
temperature measurement techniques were also used by
Nagaraj et al., (1978) and Gulino et al., (1986) to investigate
sliding contact temperatures and by Hartley et al., (1986) to
study the temperature distribution across shear bands in high
strain rate deformation. These applications demonstrate the

Journal of Tribology JULY 1990, Vol. 112/535

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 versatility of the infrared technique in terms of rapid frequen-
cy response and excellent spatial temperature resolution.
Here, results of an investigation into the temperatures ex-
isting at diamond-ferrite and, for comparison purposes,
diamond-steel interfaces in grinding are reported. Two con-
figurations, the contact between a single diamond tip and
workpiece and the contact between a full diamond wheel and
workpiece, were considered. The former is of fundamental in-
terest to high speed sliding indentation and grinding while the
latter is directed at developing an understanding of the
manufacture of magnetic ceramic components.
2 Experimental Procedure
The multiple-element infrared sensor used in the present ex-
perimental study consisted of 4 individual Indium Antimonide
(InSb) cells (Santa Barbara Research Corp.) and a high speed
thermal monitor (Vanzetti Systems Corp.). The cells were
mounted on a Dewar flask cooled with liquid nitrogen to 77 K.
InSb responds to radiation in the 0.65 to 5.3 micron range
which is an appropriate range for the present experiments. It
can be conveniently used in the photovoltaic mode to give
response times as low as 1 microsecond. When cooled with
liquid nitrogen, the performance of InSb improves by an order
of magnitude due to longer wavelength sensitivity and de-
creased thermal noise (Hartley et al., 1986). The detector
elements were coupled to fiber-optic lens assemblies which
transmitted the radiation from the source to the detector
plane. With the use of the multiple element sensor,
temperature measurements could be made simultaneously at
five locations. The smallest spot size achievable in the present
arrangement was 40 microns. The output of each detector ele-
ment was amplified and recorded in a multi-channel digital
storage oscilloscope.
2.1 Time Constant Determination. The detector was
calibrated both statically and dynamically. Static calibration
was performed by exposing it to a standard infrared source.
Dynamic calibration was performed in two different ways.
(a) A camera shutter was placed between a calibrated in-
frared source and the detector. The shutter opening was con-
trolled to expose the source for periods as short as 100
milliseconds.
(b) The detector was exposed to the calibrated infrared
source through a hole near the periphery of a spinning
aluminum disk. This scheme utilizes a situation that is almost
identical to that of the high speed grinding experiment.
The time constants of the detector elements were deter-
mined as the time taken for the response to reach 63 percent of
the final value for a step temperature input. Each detector ele-
ment was calibrated separately and the responses of the 4 InSb
elements were almost identical to each other. A sample of this
output in the 100-300°C temperature range is shown in Fig. 1
to give a measure of the sensitivity of the detector where sen-
sitivity is defined as the change of the output voltage due to a
unit change in temperature. Beyond the highest temperature
shown in Fig. 1, the relationship between the detector output
voltage and the temperature was linear, with the maximum
deviation from linearity in this region less than 1.5 percent.
The time constants of these InSb cells are 6.8 microseconds.
After 2.5 time constants of observation time the static and
dynamic calibrations are almost identical. The Vanzetti high
speed detector had a time constant of 7.4 microseconds. A
calibration test was also conducted to check the cross-
sensitivity between the detector elements such as the change in
the output of an element due to radiation incident on adjacent
elements. The technique of Hartley et al. (1986) was used for
this purpose. The maximum cross-talk was about 4 percent
from adjacent elements. The results reported here were not ad-
justed for this cross-talk.
536 / V o l . 112, JULY 1990
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25.0 r
Detector
Out
Put20.0 -
(mV)
15.0 -
10.0 -
5.0 - /
0 J 1 I 1
0.0 100.0 200.0 300.0 400.0
Temperature, T(C)
Fig. 1 Calibration curve for the infrared detector for a 40 /im spot size
2.2 Emissivity. Emissivity measurements were made on
the diamond tip and the Ni-Zn ferrite samples used in the
study. The diamond tip emissivities were measured both
before and after rubbing against the ferrite to see if there were
any changes. This was done because the diamond tip that is
observed during the grinding experiments has repeatedly come
into contact with the Ni-Zn ferrite. However, there was no
change in the emissivity before and after rubbing. The
specimen was heated to known temperatures in the range
50-680 °C and infrared radiation emitted by the specimen was
compared with radiation emitted by a blackbody source in the
same range. From these measurements the effective emissivity
of the specimen could be determined.
Emissivity compensation was conducted by direct emissivity
measurement as well as from multiwavelength radiation
measurements over a wavelength window. The temperature
values obtained in both cases were in good agreement with
each other, see Smith et al. (1957) and Doebelin (1983) for a
general discussion of emissivity compensation procedures and
Weichert and Schonert (1978) for a description of its use while
measuring the temperature near a moving crack tip.
The effective emissivity of the diamond tip was found to be
0.19 and that of ferrite was 0.81 at 680°C. The emissivity
change with temperature was marginal at temperatures over
500°C. When the diamond tip was heated to 680°C for 1 hour
the emissivity fluctuated by about 0.02 from the above value.
In all of the experimental measurements the above emissivity
values were used. Corrections were also made for the radiation
acceptance angle of the multiple element sensor.
2.3 Thermal Properties. Thermal diffusivity (K), specific
heat (cp), and bulk density ip) were determined. The thermal
conductivity (K) was calculated as the product of these quan-
tities, that is K=Kpcp. Thermal diffusivity was measured
using the laser flash technique, specific heat was measured
using a differential scanning calorimeter, and the bulk density
was calculated from the samples' mass and geometry.
Thermal diffusivity was measured using the flash method in
which the front face of a small disc-shaped sample is subjected
to a short laser burst and the resulting temperature rise on the
rear face is recorded. The apparatus consists of a Korad K2
laser; a high vacuum system, including a bell jar with windows
for viewing the sample; a tantalum tube heater sur-
rounding a sample-holding assembly; an infrared detector; ap-
propriate electronics; and a mini-computer-based, digital,
data-acquisition system capable of taking data accurately in
the 40 microsecond and longer time domain. Specific heat was
measured using a standard Perkin-Elmer DSC-2 differential
scanning calorimeter with sapphire as the reference material.
Transactions of the ASME
 Table 1 Material properties
Temperature
Property Ferrite Diamond
E(Young's Modulus) 191 GPa 1000 GPa
T(C) 1200
& steel 1
1000 - 1
KPoisson's Ratio) 0.2 0.2
800
• ferrite
- I
K(Thermal Conductivity) 8 W/m/C 1000 W/m/C
*
c(Specific Heat) 0.81 J/gm/C 0.525 J/gm/C
600

400
-
t t
p(Density) 5.3 gm/cc 3.5 gm/cc
200 -

3 10 20 30 4
Velocity, V(m/sec)
Fig. 3 Single diamond abrasive grain tip temperature for steel and fer-
rite at different velocities (grain depth of cut = 0.01 mm, table veloci-
ty = 23.4 mm/s)

P6 C
Temperature
;!
OPTICAL T(C) 600
LENS ASSEMBLY
n
500 >
400

300

200
ii

100

0
0 5 10 15 20

time, t(milliseconds)
Fig. 4 Decay of single diamond abrasive grain tip temperature with
OSCILLOSCOPE - time after contact against ferrite (V = 37 m/s)

Fig. 2 Schematic of the experimental arrangement used for the
temperature measurement
Bhushan (1987) gives further details concerning thermal
property determination.
These techniques were used to obtain the thermal property
values at 80°C for ferrite given in Table 1. The properties for
the diamond were taken from Chrenko and Strong (1975) and
are also given in Table 1. These properties were used in the
analysis (Section 4).
2.4 Single Point Grinding Force Measurement. Shaw
(1984a) showed that a dynamometer with a high natural fre-
quency is required to measure single point grinding forces. In
this study the normal and tangential forces during single point
diamond grinding were measured by mounting the Ni-Zn fer-
rite sample on a two-component piezoelectric dynamometer
(Kistler). The dynamometer used in the single grain force
measurement consisted of two piezocrystals (one for the nor-
mal force and one for the tangential force) coupled to a charge
amplifier. The output was recorded on a four-channel storage
oscilloscope. The natural frequency of the piezo-charge
amplifier system was 24.8 KHz, sufficient for both single grain
forces to be recorded. The natural frequency of the system was
inherently controlled by that of the charge amplifier. This
natural frequency was measured both by "impulse" and step
loading at the input while recording the output response.
3 Temperature Measurements
3.1 Single Point Temperatures. Figure 2 is a schematic of
the experimental arrangement used in the temperature
measurement studies. The diamond abrasive grain with an ap-
proximately hemispherical tip of diameter 15 /tim was mounted
on the periphery of an aluminum disk. The multiple element
InSb detector monitored the radiation from the diamond cut-
ting point just after it grinds and passes over the hole (approx-
imately 2 mm in diameter) in the workpiece. At a disk
peripheral velocity of 35 m/s, the detector was exposed to
radiation for a period of about 20 microseconds, which is
about 3 times the time constant of the detector. Thus it was
possible to obtain a measurement of the average grain tip
temperature. Emissivity corrections were made directly
through the sensor electronics after the emissivity of the dia-
mond tip had been measured directly as described earlier.
Figure 3 shows the measured average diamond tip
temperature during the single point grinding of Ni-Zn ferrite
and heat-treated 1045 carbon steel. The average diamond tip
temperature, just after it grinds the Ni-Zn ferrite, is between
550°C and 700°C. For diamond-steel contact, the tip
temperature is somewhat higher, around 900-1200°C. In both
instances the diamond temperature increases with increasing
sliding velocity.
3.2 Decay of the Diamond Tip Temperature. In order to
obtain the decay of the diamond tip temperature after it grinds
and leaves the workpiece, fiber-optic pick-up probes were
mounted at 90 degree intervals along the arc of rotation of the
wheel (see inset in Fig. 4). The faces of these fiber-optic probes
were kept at a distance of about 3.5 mm from the diamond tip
and picked up incident radiation from the tip when it passed in
front of them. Figure 4 shows the average temperature of the
diamond tip at various times after cutting Ni-Zn ferrite. The
tip temperature is seen to decay rapidly to about 150°C within
three-quarters of a revolution (15 milliseconds) after cutting.

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 Frequency (%) u
80.0 (6 = 0°)
n
ITT-
0.0 200.0 40O.0 600.0 800.0
Temperature, T(C)
Fig. 5(a) Histograms of cutting temperatures for full wheel grinding
(320 grit size diamond, V = 32 m/s, depth of cut = 0.02 mm) immediately
after contact
100.0
Frequency(%)
80.0 (8 = 90°)
s>]
0.0 200.0 400.0 600.0 800.0
Temperature, T(C)
Fig. 5(b) Histograms of cutting temperatures for full wheel grinding
(320 grit size diamond, V = 32 m/s, depth of cut = 0.02 mm) 1/4 revolution
after contact
This measurement suggests that the diamond tip nearly attains
room temperature before it begins the'next cut. Such a cooling
was pointed out by Kops and Shaw (1983). In light of these
observations, it is reasonable to conclude that the diamond tip
temperature variation is essentially cyclic from one cut to
another, assuming that there is no wear of the tip.
3.3 Full Grinding Wheel Temperatures. In practice, the
grinding of Ni-Zn ferrite is carried out using a complete
grinding wheel containing diamond abrasives bonded
together, rather than by a single diamond point. Temperature
measurements were conducted on a complete resin bonded
diamond wheel of 320 grit size. The configuration employed
was similar to that shown in Fig. 2. The diamond wheel was
trued using a rotary truing device (Norton Company) and
dressed with an aluminum oxide stick, to maintain concen-
tricity to within 2.5 microns. The measured temperature is the
average temperature of a 40 micron spot (the sensor spot size)
on the wheel. The emissivity of the wheel material was
measured to be about 0.62 which represents an average value
over the abrasive and the bond material.
Figure 5 shows histograms of the temperatures of various
cutting points over one revolution of the wheel. The
measurements were made at 6 = 0 deg (through the hole in the
workpiece) and at 6 = 90 deg (after a quarter revolution of the
wheel). These observations were made by recording and stor-
ing the output voltage in a digital storage oscilloscope (sampl-
ing time was 2 microseconds). The digital memory was ac-
tivated by a photo-trigger which is sensitive to reflection from
a target attached to the wheel side, following Ueda et al.,
(1985). This also made it possible to measure the same part of
the wheel face, so that the progress of the cutting grain
temperatures can be observed as grinding proceeds. From Fig.
538/Vol. 112, JULY 1990
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2oo c
, ' I ^ . ffmsacs
8 •msey
Fig. 6 Oscilloscope trace of the temperature along the periphery of
out-of-round diamond wheel (400 grit size) immediately after grinding
ferrite (wheel rotational speed = 1800 rpm)
1O0O.O
5 it is seen that the average diamond wheel temperature varied
between 620°C, right after contact, and 500°C, a quarter of a
revolution after contact. The variations in temperature be-
tween the different cutting points is probably due to the varia-
tion in their tip geometries and different projections out of the
surrounding bond.
3.4 Effect of Wheel-out-of-Roundness on the
Temperature. The effect of wheel concentricity on the
grinding temperature was qualitatively studied using an out-
of-round wheel. Figure 6 shows an oscilloscope trace of the
temperature along the periphery of this out-of-round diamond
wheel (400 grit size) immediately after grinding Ni-Zn ferrite.
The peaks in the temperature signal corresponded with lobes
(or projections) that had been artificially generated on the
wheel surface by nonuniform dressing. The spacing between
the peaks of the temperature signal correspond to the spacing
1000.0 between the lobes on the wheel surface (measured with a dial
indicator). This experiment demonstrates that an out-of-
round wheel can result in localized temperature pulses, in ad-
dition to force pulses and vibrations.
3.5 Subsurface Ferrite Temperature. A small blind hole
was drilled from the back side of the Ni-Zn ferrite sample ex-
tending almost all the way (to within 7 microns) up to the
ground surface. The hole was then extrude honed with a
polishing paste to make the surfaces smooth. A fiber optic
pick-up was embedded in the hole to pick up the radiation
from the bottom face of the hole. The emissivity corrections
made here were based on the measured ferrite emissivity.
Grinding was carried out with a resin bonded 320 grit size dia-
mond wheel. The temperature signal from the bottom hole
face was monitored continuously as the grinding wheel ap-
proached the hole. The peak temperature obtained at this
depth was around 370°C. This indicates that the temperature
at a depth of 7 microns is approximately 370 °C for a cor-
responding average surface temperature under identical condi-
tions of 620°C (Fig. 5). It should be pointed out that no cor-
rections were made for infrared radiation being emitted from
the lateral faces of the hole. Therefore the measured subsur-
face temperature is somewhat overestimated.
3.6 Influence of Chips on the Temperature Signal. Grind-
ing with a full wheel results in a significant amount of chip
production. Shaw (1984b) and Malkin (1984) point out that it
is important to pay attention to the influence of the scattered
chips, which can sometimes oxidize (exothermic reaction),
with an associated increase in their temperature. In the present
measurements, very few chips could be seen in the workpiece
hole (Fig. 2) containing the sensor. Also, few chips struck the
sensor probes beyond an angle of 0 = 45 deg (Fig. 4). So their
contribution to the measured temperature signals is thought to
be negligible. Oxidation of the chips should be negligible in the
case of Ni-Zn ferrite, which is already in a highly oxidized
state. Qualitative evidence for this can be seen from the fact
that very few sparks are produced during ferrite grinding com-
pared to steel grinding.
Transactions of the ASME
 2000

Temperature
T(C)
1500

1000

500

Fig. 7 Moving point and distributed heat sources

4 Analysis of Single Point Diamond Tip Temperatures

An analytical model was used to calculate the temperature
of the diamond tip in contact with the workpiece for single Contact radius, a(|im)
point grinding. The analysis utilized the solution for a heat Fig. 8 Comparison of measured and calculated single diamond
source moving with uniform velocity across an insulated sur- abrasive grain tip temperatures tor ferrite (N = 0.71 Newtons, n = 0.25)
face found in Carslaw and Jaeger (1959). A line source of heat
of strength Q per unit length per unit time moves with velocity Table 2 Measured forces
V to the right along the surface of an insulated half space
(Figure 7). The surface temperature is given as Wheel velocity = 37 m/sec
Work velocity = 23.4 mm/sec
Q -*T
;
irK •.(-f*)
2
(1) Depth of cut == 0.01 mm
where K is the thermal conductivity, (3= V/K, K = K/pc is the Normal force 0.71 Newtons
thermal diffusivity, p is the density, c is the specific heat, Tangential force 0.18 Newtons
x' =x— Vt where t is time, and K0 is a Modified Bessel Func-
tion of the second kind. Equation (1) can be used as a Green's Coefficient of friction 0.25
Function to calculate the surface temperature due to a
distributed heat source. This is accomplished by writing
Q = q(£)d£. and*' =x' - £ in equation (1), where <?(£) is the where the subscripts F and D refer to ferrite and diamond,
strength of the distributed source. These equations are then in- respectively.
tegrated with respect to £. If q is uniform from £= — a to The surface temperature distribution caused by a grain tip
£ = a, the integrals can be evaluated in closed form (Farris and of length 2a can now be calculated. The two dimensional
Chandrasekar, 1989). analysis assumes that the heat flux distribution is uniform in
In order to calculate the temperature using equation (1), the the direction perpendicular to sliding. The three dimensional
amount of heat generated must be estimated. The total fac- heat flux distribution is approximated by using the average
tional energy dissipated per unit time during sliding can be heat generated per unit area in the two dimensional model.
calculated as The surface temperature distribution is integrated numerically
W=ixNV (2) to yield an average diamond tip temperature. The average dia-
mond tip temperature is shown in Fig. 8 as a function of con-
where jt, is the coefficient of friction and N is the normal force tact radius and sliding velocity for the forces given in Table 2.
applied to the grain. Equation (2) requires the normal and Comparison of calculated and measured temperatures re-
tangential single point grinding forces to be measured. Table 2 quires the contact size. Assuming Hertz contact by a diamond
gives the measured forces and the coefficient of friction, spherical indenter of radius 7.5 /on loaded by N = 0.71
which is estimated as the ratio of the tangential and normal Newtons, one can claculate a maximum contact pressure of 41
forces, for a given set of grinding conditions. GPa which is well above the Vickers Hardness of ferrite,
For a circular grain contact of radius a, the heat generated H = 7.35GPa. Therefore, the contact area is approximated as
per unit area of contact per unit time is the normal load over the hardness. Assuming circular contact,
the contact radius is calculated as
(3)
/I \1/2
(6)
Most of the heat generated is conducted into the diamond a=( N/Hj « 5.55/im
grain while the remainder is conducted into the ferrite The Peclet number for this radius is L= 150 for K=25 m/s.
workpiece. Ramanath and Shaw (1988) have shown that for The heat partitioning model equation (5)) is valid. The
large Peclet number measured temperatures are shown in Fig. 8 assuming a=5.55
2Va (jm. The agreement between the measured and calculated
L= >20 (4) temperatures is better than expected since the temperature
analysis is two dimensional.
the fraction of heat conducted into the ferrite is
5 Discussion
1 The surface temperature generated by a single diamond
R- = 0.12 (5) abrasive immediately after contact with ferrite and steel is
(Kpc)D measured and is much higher, when in contact against steel
1+
(KPc)F (900-1200 °C) than during contact with ferrite (5 50-700 °C)

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Flg.9 Scanning electron micrograph of the diamond tip after grinding
steel In an argon atmosphere showing spherical particles
under identical conditions. A two-dimensional model based
on the moving heat source was used to predict the temperature
for the single diamond abrasive grain sliding against ferrite.
The agreement was surprisingly good since this is an inherently
three-dimensional process. The analysis procedure will be used
to develop a model for the mechanics of grinding in the future.
Such a model would be useful for the prediction of grinding
induced damage such as residual stresses and cracking.
Figure 9 shows a scanning electron micrograph of the dia-
mond tip after grinding steel in an argon atmosphere to pre-
vent oxidation of the chips. The presence of small spherical
particles close to the diamond tip (identified possibly as iron
from x-ray analysis in the SEM) indicates that localized
melting of the steel may have occurred at the grinding inter-
face. Under these conditions the infrared sensor, observing the
grain through a hole in the steel sample, measured
temperatures in the vicinity of 1400·C. Even though this
temperature is lower than the melting point of 1045 steel, it
must be pointed out that the measurements are conducted dur-
ing the decay of the actual interface grinding temperature (im-
mediately after grinding). Furthermore, the measured tip
temperature is an average over a 40 micron spot diameter on
the diamond tip. Hot spot regions much smaller than this are
bound to exist in the diamond grain.
Komanduri and Shaw (1975), Malkin (1984), and Ramanath
et al (1987) also observed spherical particles produced during
grinding. While Malkin (1984) attributes these particles to
melting, Komanduri and Shaw (1975) suggest an alternative
hypothesis for their formation. They attribute the formation
of these spherical particles to platelets of the work material on
the chip curling up and possibly sticking to one another as a
consequence of nonequilibrium density of electrons on the
freshly generated surfaces caused by the Kramer effect.
Measurements of the interface temperature, when grinding
ferrite with a resin bonded diamond wheel, indicate that
average full wheel temperatures are around 620·C. However,
individual diamond grains on the grinding wheel show a
distribution of temperatures (Fig. 5) which is possibly due to
varying tip conditions and the varying amount of projections
from the grinding wheel bond. This latter effect is dramatical-
ly illustrated by the temperature pulses observed along the
periphery of an out-of-round grinding wheel (Fig. 6). At a
depth of 7 microns below the ground surface, the temperature
was estimated as 370·C, suggesting the presence of sharp
temperature gradients near the ground surface.
The cooling of the diamond abrasive tip is rapid; in one in-
stance its temperature was observed to decrease from about
650·C to 150·C in 15 milliseconds (or about three quarters of
a revolution of the wheel). Therefore, there is little chance for
the grain temperature to build up from one grinding cut to
another, confirming earlier comments made by Shaw (1984b).
Future work will include improved interface temperature
measurements with smaller spot size sensors, parametric
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studies of the interface and subsurface work temperatures,
refinements of the analytical model, and investigations of the
effects of coolants on the abrasive temperature. It is hoped
that these sutdies would enable control of the grinding
temperatures.
6 Conclusions
The major conclusions of this research are enumerated as
follows:
1. Under identical single point grinding conditions, the in-
terface temperature ranges from 550-770·C in ferrite and
from 900-1200·C in steel for sliding velocities ranging from 25
mls to 37 mls. For ferrite, identical grinding conditions using
a full wheel lead to higher peak temperatures.
2. A simple two-dimensional model based on the moving
heat source underestimates the measured temperature values
by about 15 percent.
3. For full wheel grinding, the measured temperature value
in ferrite decreases from an average value of 620·C at the sur-
face to 370·C seven microns below the surface, indicating the
highly localized nature of the peak grinding temperatures.
4. An out-of-round grinding wheel causes temperature
spikes.
5. Localized heating of the ferrites leads to localized
temperatures above the Curie point, 200-600·C over a large
class of these materials (Snelling, 1969), which may cause
undesirable magnetic property changes.
6. The diamond abrasive grain tip is heated above the dia-
mond graphitization temperature of 850·C (Field, 1982) dur-
ing the single point grinding of steel which may contribute to
diamond wheel wear. However, graphitization is a time-
temperature reaction and the kinetics of the reaction must be
considered before it is concluded that grinding induced dia-
mond graphitization is possible.
Acknowledgment
This work was partially supported by the National Science
Foundation (NSF) through grants MSM 8706919A (Program
in Materials Engineering and Processing, Dr. R. Komanduri,
Program Monitor) and MSM 8706920 (Tribology Program,
Dr. J. Larsen-Basse, Program Monitor). We would like to
thank Dr. R. Taylor of the Thermophysical Properties
Research Laboratory at Purdue for the thermal property
determinations and D. Jacobs of the Purdue Physics Depart-
ment for help with the emissivity measurements. We are also
grateful to Prof. M. C. Shaw of Arizona State University for
loan of the Vanzetti thermal monitor.
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International Tribology Conference — Japan
Nagoya, 1990
Oct. 29 - Nov. 1, 1990
The Japanese Society of Tribologists and the Organising Committee cordially invite you to attend the
Japan International Tribology Conference, Nagoya 1990.
Information (second circular) is available from:
Secretariat of the Japan International Tribology Conference, Nagoya 1990
c/o Toyota Technological Institute
2 Hisakata
Tempaku, Nagoya
Japan 468
The official language of the conference will be English.
Journal of Tribology
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JULY 1990, Vol. 112/541