Grinding of hardened steels using optimized cooling

Grinding - the final machining process of a workpiece - requires large amounts of cutting fluids for the lubrication, cooling and removal of chips. These fluids are highly aggressive to the environment. With the technological advances of recent years, the worldwide trend is to produce increasingly sophisticated components with very strict geometric and dimensional tolerances, good surface finish, at low costs, and particularly without damaging the environment. The latter requirement can be achieved by recycling cutting fluids, which is a costly solution, or by drastically reducing the amount of cutting fluids employed in the grinding process. This alternative was investigated here by varying the plunge velocity in the plunge cylindrical grinding of ABNT D6 steel, rationalizing the application of two cutting fluids and using a superabrasive CBN (cubic boron nitride) grinding wheel with vitrified binder to evaluate the output parameters of tangential cutting force, acoustic emission, roughness, roundness, tool wear, residual stress and surface integrity, using scanning electron microscopy (SEM) to examine the test specimens. The performance of the cutting fluid, grinding wheel and plunge velocity were analyzed to identify the best machining conditions which allowed for a reduction of the cutting fluid volume, reducing the machining time without impairing the geometric and dimensional parameters, and the surface finish and integrity of the machined components.

Evaluation of different methods of cooling-lubrication in cylindrical grinding of advanced ceramic dip

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Influência da lubrirrefrigeração na qualidade superficial de metais retificados

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Cerâmicas avançadas no processo de retificação cilíndrica externa de mergulho com rebolos diamantados com a técnica da mímima quantidade de lubrificação e refrigeração otimizada

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Influência das técnicas de mínima quantidade de lubrificante, refrigeração otimizada e refrigeração convencional na qualidade de peças produzidas com aços endurecidos no processo de retificação

The influence of minimum lubrication, optimized and conventional cooling at different flows and application rates of cutting fluids on the quality of hardened-steel pieces produced by external cylindrical plunge grinding with super-abrasive grinding wheels with low CBN concentrations was verified. The analysis of the quality of the pieces was performed through the assessment of the behavior of the specific energy of the grinding, roughness, roundness deviation, and the generated residual stress. By analyzing of the application ways and of the several flows and application rates of the cutting fluid, one could encounter lubrication/cooling conditions that enable the reduction in cutting fluid volume, reduction in grinding time without compromising the dimensional parameters (superficial finishing, surface integrity). Regarding the different applications of cutting fluids, it could be noted the optimized application for higher velocities has presented the best performance, demonstrating the effectiveness of the new concept of nozzle utilized.

Utilização de diferentes métodos de lubri-refrigeração na retificação cilíndrica externa de mergulho de cerâmica avançada com rebolo diamantado

Pós-graduação em Ciência e Tecnologia de Materiais - FC

Otimização da retificação tangencial plana de compósitos plásticos reforçados com fibras de carbono

Pós-graduação em Ciência e Tecnologia de Materiais - FC

Influência dos métodos de lubri-refrigeração na retificação do aço ABNT 4340 usando rebolo de CBN

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Influence of optimized lubrication-cooling and minimum quantity lubrication on the cutting forces, on the geometric quality of the surfaces and on the micro-structural integrity of hardened steel parts

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

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.

Ecological optimization of an irreversible Brayton cycle with regeneration, inter-cooling and reheating

A mathematical model is developed for an irreversible Brayton cycle with regeneration, inter-cooling and reheating. The irreversibility are from the thermal resistance in the heat exchangers, the pressure drops in pipes, the non-isentropic behavior in the adiabatic expansions and compressions and the heat leakage to the cold source. The cycle is optimized by maximizing the ecological function, which is achieved by the search for optimal values for the temperatures of the cycle and for the pressure ratios of the first stage compression and the first stage expansion. The advantages of using the regenerator, intercooler and reheater are presented by comparison with cycles that do not incorporate one or more of these processes. Optimization results are compared with those obtained by maximizing the power output and it is concluded that the point of maximum ecological function has major advantages with respect to the entropy generation rate and the thermal efficiency, at the cost of a small loss in power.

Plant or fungal sequences? An alternative optimized PCR protocol to avoid ITS (nrDNA) misamplification

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Optimized architecture for Tyrosinase-containing Langmuir-Blodgett films to detect pyrogallol

The control of molecular architectures has been a key factor for the use of Langmuir-Blodgett (LB) films in biosensors, especially because biomolecules can be immobilized with preserved activity. In this paper we investigated the incorporation of tyrosinase (Tyr) in mixed Langmuir films of arachidic acid (AA) and a lutetium bisphthalocyanine (LuPc2), which is confirmed by a large expansion in the surface pressure isotherm. These mixed films of AA-LuPc2 + Tyr could be transferred onto ITO and Pt electrodes as indicated by FTIR and electrochemical measurements, and there was no need for crosslinking of the enzyme molecules to preserve their activity. Significantly, the activity of the immobilised Tyr was considerably higher than in previous work in the literature, which allowed Tyr-containing LB films to be used as highly sensitive voltammetric sensors to detect pyrogallol. Linear responses have been found up to 400 mu M, with a detection limit of 4.87 x 10(-2) mu M (n = 4) and a sensitivity of 1.54 mu A mu M-1 cm(-2). In addition, the Hill coefficient (h = 1.27) indicates cooperation with LuPc2 that also acts as a catalyst. The enhanced performance of the LB-based biosensor resulted therefore from a preserved activity of Tyr combined with the catalytic activity of LuPc2, in a strategy that can be extended to other enzymes and analytes upon varying the LB film architecture.

Optimized synthesis of the melatonin metabolite N(1)-acetyl-N(2)-formyl-5-methoxykynuramine (AFMK)

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

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.