CFD-based optimization of groove structures in silicon carbide grinding disks for ultra-precision grinding

This study investigates the challenges associated with ultra-precision machining of silicon carbide (SiC) and proposes a grinding disk design that leverages hydrodynamic pressure effects. Using computational fluid dynamics (CFD) simulations, the effects of arc-shaped groove inclination angles (0°, 30°, 60°) and corner radii (0 mm, 0.05 mm, 1 mm) on hydrodynamic pressure, vortex distribution, shear flow behavior, and liquid film thickness uniformity were systematically analyzed. Results demonstrate that an arc-shaped groove with a 60° inclination angle and a 0.05 mm corner radius generates higher hydrodynamic pressure, produces uniform and dense vortex patterns, facilitates full development of shear flow, and significantly improves liquid film uniformity. These findings offer a theoretical foundation for the design of high-performance hydrodynamic grinding disks, supporting the advancement of efficient, high-quality, and stable ultra-precision grinding processes for silicon carbide.