Form error in-process optical measurement is among one of the most important surface profile measurement techniques. Inaccessibility problem is caused by the application of opaque coolant during the surface grinding process. A new method using water beam in creating a transparent area for direct access by measurement beam to surface of workpiece was proposed previously....[ Read more ]

Form error in-process optical measurement is among one of the most important surface profile measurement techniques. Inaccessibility problem is caused by the application of opaque coolant during the surface grinding process. A new method using water beam in creating a transparent area for direct access by measurement beam to surface of workpiece was proposed previously.

To gain better understanding of the proposed method, this project studied the integrated effect of five input parameters on the size of transparent window generated with the CFD modeling approach. A stable CFD model was successfully constructed. Stable range of conditions for transparent window size value determination was identified. The development of the CFD model used for the study was reported. CFD generated results are being compared with the results of the collaborated experiment both qualitatively and quantitatively.

Compared the CFD result against the result from the collaborated experiment, it was founded that the CFD model is capable in identifying transparent window size rate with changing parameters. The CFD model was also found to have difficulties in simulating the experimental value of transparent window size in specific parameter conditions like coolant concentration at 20%. Reasons were found to be related to the instability of the experimental data and suggestions for improvements were made.

By adopting the various solution representation methods given by the CFD program, new insights to future design and direction for further studies were identified. It was found that smaller water channel diameter will give better conditions for transparent window generation. Slower workpiece velocities below certain critical value approximately 20mm/s will a cause reduction in transparent window size due to the definition of problem. Suggestions for future design and applications of the proposed method were made.