Modelling of Temperature Field and Stress–Strain State of the Workpiece with Plasma Coatings during Surface Grinding

Round  1

Reviewer 1 Report

The paper can be considered for the publication.

Author Response

Regarding the Reviewer 1 report, the introduction has been improved so that it includes relevant references as well as the presented research background.

Reviewer 2 Report

This paper mainly established a mathematical model of the temperature field and the stress-strain state for the process of grinding wear-resistant plasma coatings. The mathematical model considered structural changes of the coating material. In general, this manuscript has been organized well. However, before acceptance to publish, some revisions are required, as follows:

(1) The topic of the research is on mathematical modelling of the temperature field and the stress-strain state for the workpiece with plasma coatings material during surface grinding, but few of literature is systematically reviewed. The literature about mathematical modelling of plasma coatings material in grinding in recent years should be reviewed.

(2) In order to improve the Introduction part of this manuscript, some literatures are suggested to be cited, for example, which discusses the surface grinding operation of difficult-to-cut materials (e.g., International Journal of Advanced Manufacturing Technology 2019, 100: 445-455 and 2019, 100: 153-165 and 2018, 97: 1649-1661) or which studies the finite element analysis (e.g., Precision Engineering 2018, 54: 70-80 and 2018, 52: 192-200).

(3) At present, the third part of this manuscript seems redundant. All parameters are well-known facts to researchers. On the contrary, some unusual parameters are not presented. The third part of this manuscript should include all annotations about nomenclature, if needed.

(4) The authors are advised to give further explanation about some parameters in this manuscript, such as thermal diffusivity α. Thermal diffusivity α is related to change of density ρ, thermal conductivity λ and specific heat c. The authors should very careful check the manuscript about this kind of problem.

(5) In this manuscript, the authors claimed that the mathematical model considered structural defects of the coating material, such as pore in coating material. However, the analysis of the temperature field and stress-strain state about plasma coatings during the grinding is based on plane two-dimensional model. It is well known that temperature field and stress-strain state about plasma coatings are influenced by the porosity, pore space distribution, pore size and so on. Therefore, the plane three-dimensional model is more suitable for analysis of temperature field and stress-strain state about plasma coatings material in grinding.

(6) In the seventh part of this manuscript, the grinding parameters are optimized. Recommended grinding parameters are consistent with the max value of the grinding parameters range. In other words, the grinding parameters, such as grinding depth, longitudinal motion and transverse, have the potential to enhance machining efficiency.

(7) In this manuscript, the mathematical model of the temperature field and the stress-strain state of the plasma coatings material workpiece is established in grinding. But how about are the relevant experimental results? How to measure the grinding temperature on line? How do the authors validate the reliability and accuracy of the mathematical model?

Author Response

Regarding the Reviewer 2 report, the introduction has been improved and the following suggestions were considered:

(1)    The literature about mathematical modelling of grinding process has been reviewed: [4 – 9, 11, 12].

(2)    Literature references have been added:

[6] Zhou, H.; Ding, W.; Liu, C. Material removal mechanism of PTMCs in high-speed grinding when considering consecutive action of two abrasive grains. The International Journal of Advanced Manufacturing Technology 2019, 100, 153–165.

[7] Dai, C.; Ding, W.; Zhu, Y.; Xu, J.; Yu, H. Grinding temperature and power consumption in high speed grinding of Inconel 718 nickel-based superalloy with vitrified CBN wheels. Precision Engineering 2018, 52 (2018), 192–200.

[8] Qian, N.; Ding, W.; Zhu, Y. Comparative investigation on grindability of K4125 and Inconel718 nickel-based superalloys. The International Journal of Advanced Manufacturing Technology 2018, 97, 1649–1661.

[9] Gu, Y.; Li, H.; Du, B.; Ding, W. Towards the understanding of creep-feed deep grinding of DD6 nickel-based single-crystal superalloy. The International Journal of Advanced Manufacturing Technology 2019, 100, 445–455.

(3)    The third part considering nomenclature has been deleted.

(4)    Explanations about grinding parameters is given after the equations in which they are presented for the first time in the manuscript.

(5)    Plane thermo-elastic problem consider structural defects located close to the contact zone between a grinding wheel and a workpiece as those defects tend to further propagation because of high temperatures and stresses. This model allows to analyse an influence of the structural defects on cracking resistance depending on their location towards the processed surface. Due to the complexity of calculations for three-dimensional model of thermo-mechanical phenomena and the completeness of statements obtained on the basis of two-dimensional model, it was decided to consider two-dimensional model in order to receive strength and fracture criteria to provide zero-defect grinding of plasma coatings.

(6)    The developed mathematical model will be used as a basis for further CAD system development. This system implies optimization of grinding process focused on enhancing machining efficiency, including productivity of material processing. So the Reviewer’s comment is absolutely right about  future prospects of the presented research.

(7)    The relevant experimental results are presented in the sixth part of the manuscript “Experimental Validation” which was added after the revision.

Reviewer 3 Report

Scientific locks are not stated. This interesting work is a direct application of what exists in literature. This perception may change if you insist on your contributions in this study and develop them.

Results must be compared to experimental results. Those can be taken in literature if you referenced them.

Author Response

Regarding the Reviewer 3 report, the introduction has been improved so that it includes relevant references as well as the presented research background. The design of the manuscript has been improved. The experimental results have been added (part 6 of the manuscript).

(1)    Contribution of this study is mathematical model of the temperature thermal field during the the plasma coatings grinding process and the system of strength and fracture criteria that provide zero-defect grinding.

(2)    Experimental results have been added to the manuscript.

Round  2

Reviewer 3 Report

Authors improved the paper regarding the recommendation.