Studies on the cooling minimum quantity and conventional cooling at hardened steels in grinding process

The purpose of this work is to explain the concept of cutting fluids reasonable usage through the fluid minimum quantity in grinding processes. on that purpose, the development of a new nozzle and an own and adequate methodology should be required in order to obtain good results and compare them to the conventional methods. The analysis of the grinding wheel/cutting fluid performance was accomplished from the following input parameters: flow rate variation by nozzle diameter changes (three diameters values: 3mm, 4mm and 5mm), besides the conventional round nozzle already within the machine. Integral oil and a synthetic emulsion were used as cutting fluids and a conventional grinding wheel was employed. The workpieces were made of steel VC 131, tempered and quenched with 60HRc. Thus, as the flow rate and the nozzle diameter changes, keeping steady fluid jet velocity (equal to cutting velocity), attempted to find the best machining conditions, with the purpose to obtain a decrease on the cutting fluid volume, taking into consideration the analysis of the process output variables such as cutting strength, cutting specific energy, grinding wheel wear and surface roughness. It was verified that the 3mm diameter optimized nozzle and the integral oil, in general, was the best combination among all proposed.

Automatic detection of thermal damage in grinding process by artificial neural network

Esse trabalho tem por objetivo o desenvolvimento de um sistema inteligente para detecção da queima no processo de retificação tangencial plana através da utilização de uma rede neural perceptron multi camadas, treinada para generalizar o processo e, conseqüentemente, obter o limiar de queima. em geral, a ocorrência da queima no processo de retificação pode ser detectada pelos parâmetros DPO e FKS. Porém esses parâmetros não são eficientes nas condições de usinagem usadas nesse trabalho. Os sinais de emissão acústica e potência elétrica do motor de acionamento do rebolo são variáveis de entrada e a variável de saída é a ocorrência da queima. No trabalho experimental, foram empregados um tipo de aço (ABNT 1045 temperado) e um tipo de rebolo denominado TARGA, modelo ART 3TG80.3 NVHB.

Study of thresholds to burning in surface grinding process

This work aims at finding out the threshold to burning in surface grinding process. Acoustic emission and electric power signals are acquired from an analog-digital converter and processed through algorithms in order to generate a control signal to inform the operator or interrupt the process in the case of burning occurrence. The thresholds that dictate the situation of burn and non-burn were studied as well as a comparison between the two parameters was carried out. In the experimental work one type of steel (ABNT-1045 annealed) and one type of grinding wheel referred to as TARGA model 3TG80.3-NV were employed. Copyright © 2005 by ABCM.

Global analysis of aerodynamics deflectors efficiency in the grinding process

The conventional, grinding methods in some cases are not very efficient because the arising of thermal damages in the pieces is very common. Optimization methods of cutting fluid application in the grinding zone are essential to prevent thermal problems from interaction of the wheel grains with the workpiece. surface. The optimization can happen through the correct selection of the cut parameters and development of devices that eliminate air layer effects generated around the grinding wheel. This article will collaborate with the development of an experimentation methodology which allows evaluating, comparatively, the performance of the deflectors in the cutting region to minimize the air layer effect of the high speed of the grinding wheel. The air layers make the cutting fluid jet to dissipate in the machine. An optimized nozzle was used in order to compare the results with the conventional method (without baffles or deflectors) of cutting fluid application. The results showed the high eficciency of the deflectors or baffles in the finish results. Copyright © 2006 by ABCM.

Monitoring the dressing operation in the grinding process

This work was based on a methodology of development and experimentation, and involved monitoring the dressing operation by processing the acoustic emission and electric power signals to detect the optimal dressing moment. Dressing tests were performed in a surface grinding machine with an aluminium grinding wheel. Dressing analysis software was developed and used to process the signals collected earlier in order to analyse not only the dressing parameters but also the software's ability to indicate the instant when the dressing operation could be concluded. Parameters used in the study of burn in grinding were implemented in order to ascertain if they would also prove efficient in monitoring dressing. A comparative study revealed that some parameters are capable of monitoring the dressing operation. It was possible to verify the parameters effectiveness that today are utilised in burning to monitor dressing as well as to create new parameters for monitoring this operation. Copyright © 2009, Inderscience Publishers.

Grinding process monitoring based on electromechanical impedance measurements

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In-process grinding monitoring by acoustic emission

This work aims to investigate the efficiency of digital signal processing tools of acoustic emission signals in order to detect thermal damages in grinding process. To accomplish such a goal, an experimental work was carried out for 15 runs in a surface grinding machine operating with an aluminum oxide grinding wheel and ABNT 1045. The acoustic emission signals were acquired from a fixed sensor placed on the workpiece holder. A high sampling rate data acquisition system at 2.5 MHz was used to collect the raw acoustic emission instead of root mean square value usually employed. Many statistics have shown effective to detect burn, such as the root mean square (RMS), correlation of the AE, constant false alarm (CFAR), ratio of power (ROP) and mean-value deviance (MVD). However, the CFAR, ROP, Kurtosis and correlation of the AE have been presented more sensitive than the RMS.

In-process thermal damage detection in grinding with monitoring via Internet

This work aims the development of a dedicated system for detection of burning in surface grinding process, where the process will constantly be monitored through the acoustic emission and electric power of the induction motor drive. Acquired by an analog-digital converter, algorithms process the signals and a control signal is generated to inform the operator or interrupt the process in case of burning occurrence. Moreover, the system makes possible the process monitoring via Internet. Additionally, a comparative study between parameters DPO and FKS is carried through. In the experimental work one type of. steel (ABNT-1020 annealed) and one type of grinding wheel referred to as TARGA, model ART 3TG80.3 NVHB, were employed.

Analysis of the different forms of application and types of cutting fluid used in plunge cylindrical grinding using conventional and superabrasive CBN grinding wheels

The work reported here involved an investigation into the grinding process, one of the last finishing processes carried out on a production line. Although several input parameters are involved in this process, attention today focuses strongly on the form and amount of cutting fluid employed, since these substances may be seriously pernicious to human health and to the environment, and involve high purchasing and maintenance costs when utilized and stored incorrectly. The type and amount of cutting fluid used directly affect some of the main output variables of the grinding process which are analyzed here, such as tangential cutting force, specific grinding energy, acoustic emission, diametrical wear, roughness, residual stress and scanning electron microscopy. To analyze the influence of these variables, an optimised fluid application methodology was developed (involving rounded 5, 4 and 3 turn diameter nozzles and high fluid application pressures) to reduce the amount of fluid used in the grinding process and improve its performance in comparison with the conventional fluid application method (of diffuser nozzles and lower fluid application pressure). To this end, two types of cutting fluid (a 5% synthetic emulsion and neat oil) and two abrasive tools (an aluminium oxide and a superabrasive CBN grinding wheel) were used. The results revealed that, in every situation, the optimised application of cutting fluid significantly improved the efficiency of the process, particularly the combined use of neat oil and CBN grinding wheel. (c) 2005 Elsevier Ltd. All rights reserved.

Analysis of surface integrity for minimum quantity lubricant - MQL in grinding

The quality of machined components is currently of high interest, for the market demands mechanical components of increasingly high performance, not only from the standpoint of functionality but also from that of safety. Components produced through operations involving the removal of material display surface irregularities resulting not only from the action of the tool itself, but also from other factors that contribute to their superficial texture. This texture can exert a decisive influence on the application and performance of the machined component. This article analyzes the behavior of the minimum quantity lubricant (MQL) technique and compares it with the conventional cooling method. To this end, an optimized fluid application method was devised using a specially designed nozzle, by the authors, through which a minimum amount of oil is sprayed in a compressed air flow, thus meeting environmental requirements. This paper, therefore, explores and discusses the concept of the MQL in the grinding process. The performance of the MQL technique in the grinding process was evaluated based on an analysis of the surface integrity (roughness, residual stress, microstructure and microhardness). The results presented here are expected to lead to technological and ecological gains in the grinding process using MQL. (c) 2006 Elsevier Ltd. All rights reserved.

The minimum quantity of lubricant (MQL) technique in the surface grinding of steel

This research aimed to analyze the viability of the minimum quantity of lubricant (MQL) technique towards different methods of lubri-refrigeration in surface grinding of steel, considering process quality, wheel life and the viability of using cutting fluids The proposal methods were the conventional (abundant fluid flow), the minimum quantity lubrication (MQL) and the optimized method with Webster nozzle (rounded) This analysis was carried out in equal machining conditions, through the assessment of variables such as grinding force, surface roughness, G ratio (volume of removed material/volume of wheel wear), and microhardness The results showed the possibility of improvement of the grinding process Besides, there is the opportunity for production of high quality workpieces with lower costs The MQL technique showed efficiency in machining with lower depths of cut The optimized method with Webster nozzle applies the fluid in a rational way, without considerable waste Hence, the results show that industry can rationalize and optimize the application of cutting fluids, avoiding inappropriate disposal, inadequate use and consequently environment pollution

The behaviour of resin-bond diamond wheels in the grinding of advanced ceramics

Results are reported of the behaviour of the plane tangential grinding process using diamond grinding wheels. Grinding performance is analysed in terms of the wear behaviour of the wheel in the grinding of ceramic. Discussion of the results concentrates on the wear mechanism of the diamond wheel and the process of material removal.

Production grinding burn detection using acoustic emission and electric power signals

This work uses a monitoring system based on a PC platform, where the acoustic emission and electric power signals generated during the grinding process are used to investigate superficial burning occurrence in a surface grinding operation using two types of steel, three grinding conditions and an Al203 vitrified grinding wheel. Acoustic emission signals on the workpiece and grinding power were measured during a surface plunge operation until the grinding burn happened. From the results the standard deviation of the acoustic emission signal and the maximum electric power were calculated for each grinding pass. The proposed DPO parameter is the product between the power level and acoustic emission standard deviation. The results show that both signals can be used for burning detection, and the parameter DPO is the best indicator for the burning studied in this work. This can be explained by the high dispersion of the acoustic emission RMS level associated to the high power consumption when the grinding wheel lose its sharpness.

Control of thermal damage in grinding by digital signal processing of raw acoustic emission

Grinding process is usually the last finishing process of a precision component in the manufacturing industries. This process is utilized for manufacturing parts of different materials, so it demands results such as low roughness, dimensional and shape error control, optimum tool-life, with minimum cost and time. Damages on the parts are very expensive since the previous processes and the grinding itself are useless when the part is damaged in this stage. This work aims to investigate the efficiency of digital signal processing tools of acoustic emission signals in order to detect thermal damages in grinding process. To accomplish such a goal, an experimental work was carried out for 15 runs in a surface grinding machine operating with an aluminum oxide grinding wheel and ABNT 1045 e VC131 steels. The acoustic emission signals were acquired from a fixed sensor placed on the workpiece holder. A high sampling rate acquisition system at 2.5 MHz was used to collect the raw acoustic emission instead of root mean square value usually employed. In each test AE data was analyzed off-line, with results compared to inspection of each workpiece for burn and other metallurgical anomaly. A number of statistical signal processing tools have been evaluated.