Improving minimum quantity lubrication in CBN grinding using compressed air wheel cleaning

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

Application of the Minimum Quantity Lubrication (MQL) Technique in the Plunge Cylindrical Grinding Operation

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

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)

Utilization of teflon and aluminum oxide for wheel cleaning in Minimum Quantity Lubrication (MQL) grinding

Researches concerning cooling-lubrication optimization in grinding have been conducted to contribute to a more sustainable process. An alternative to flood coolant is minimum quantity lubrication (MQL), which spray oil droplets in a compressed air jet. However, problems related to wheel cleaning were reported, due to wheel loading by a mixture of chips and oil, resulting in worsening of surface quality. This work aims to evaluate the viability of Teflon and aluminum oxide for wheel cleaning, compared to MQL without cleaning and MQL with cleaning by compressed air, through the following output variables: surface roughness, roundness, wheel wear, grinding power and acoustic emission. Vickers microhardness measurements and optical microscopy were also carried out. The results showed that both materials were efficient in cleaning the wheel, compared to MQL without cleaning, but not as satisfactory as compressed air. Much work is to be done in order to select the right material for wheel cleaning.

Utilization of Minimum Quantity Lubrication (MQL) with Water in CBN Grinding of Steel

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

A study on the viability of minimum quantity lubrication with water in grinding of ceramics using a hybrid-bonded diamond wheel

With the currently strict environmental law in present days, researchers and industries are seeking to reduce the amount of cutting fluid used in machining. Minimum quantity lubrication is a potential alternative to reduce environmental impacts and overall process costs. This technique can substantially reduce cutting fluids in grinding, as well as provide better performance in relation to conventional cutting fluid application (abundant fluid flow). The present work aims to test the viability of minimum quantity lubrication (with and without water) in grinding of advanced ceramics, when compared to conventional method (abundant fluid flow). Measured output variables were grinding power, surface roughness, roundness errors and wheel wear, as well as scanning electron micrographs. The results show that minimum quantity lubrication with water (1:1) was superior to conventional lubrication-cooling in terms of surface quality, also reducing wheel wear, when compared to the other methods tested.

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

Study on the behavior of the Minimum quantity lubricant - MQL technique under different lubricating and cooling conditions when grinding ABNT 4340 steel

The behavior of the minimum quantity lubricant (MQL) technique was analyzed under different lubricating and cooling conditions when grinding ABNT 4340 steel. The comparative analysis of the residual stress values showed that residual compressive stresses were obtained under all the lubrication/cooling conditions and types of abrasive tools employed. The highest residual compressive stress obtained with the aluminum oxide grinding wheel with MQL under the condition of V= 30m/s for air and V= 40ml/h for lubricant was -376MPa against the -160MPa attained with conventional cooling, representing a 135% increase in residual compressive stress. The results show that method and quantity of lubricant and cooling are factors that influence the grinding process.

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.

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.

Analysis of the Influence of Sparkout Time on Grinding Using Several Lubrication/Cooling Methods

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

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)

Análise de métodos de lubri-refrigeração aplicados no processo de retificação cilíndrica interna de mergulho em aços endurecidos

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Valutazione funzionale ed economica di una innovativa macchina utensile in alluminio

L’oggetto di studio della presente tesi è una macchina utensile ad altra produttività con tavola rotante (transfer) che presenta numerosi elementi di innovazione rispetto a versioni precedenti. In particolare è stata ottimizzata la scelta dei materiali che compongono i vari elementi della struttura, sono stati ripensati gli impianti di servizio e, infine, è stato reso possibile l’impiego di tecnologie di lavorazione che permettono una notevole riduzione del consumo elettrico. Il transfer è costituito da una stazione di carico/scarico e da numerose stazioni di lavoro equipaggiate con moduli a tre assi che permettono di eseguire le diverse operazioni da realizzare sul componente in lavorazione. Le unità a tre assi vengono impiegate per movimentare gli elettromandrini che mettendo in rotazione gli utensili permettono l’esecuzione delle diverse lavorazioni. L’attività svolta è stata suddivisa in diverse fasi: nella prima è stata realizzata un’analisi funzionale che ha permesso di valutare (i) la rigidezza dell’unità a tre assi che equipaggia ogni stazione di lavoro e (ii) l’errore di posizionamento indotto dal riscaldamento delle viti di manovra che permettono la movimentazione dei tre assi della macchina. Nella seconda fase sono state valutate le potenzialità della tecnologia Minimum Quantity Lubrication (MQL) come alternativa ecologica ed economica alla tradizionale tecnica di lubrorefrigerazione con emulsione. La tecnica MQL consiste nel nebulizzare nella zona di taglio un aerosol composto da aria e olio. In particolare è stato calibrato il sistema di generazione dell’aerosol stesso ed è stata indagata l’influenza dei diversi parametri di taglio sulla qualità della lavorazione. Infine è stata effettuata un’analisi economica che ha permesso di valutare il vantaggio economico in termini di potenza installata e consumo di energia elettrica del transfer in relazione ad una macchina utensile di pari taglia che presenta le soluzioni costruttive standard per questa tipologia di dispositivo.