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)

Influência da lubrirrefrigeração na qualidade superficial de metais retificados

Na fabricação de componentes mecânicos precisos, que necessitam de alta resistência mecânica e ao desgaste, utiliza-se o processo de retificação, para conferir o acabamento final desejado e, também, para eliminar as deformações ocorridas durante a têmpera do aço. No entanto, as condições de retificação devem ser adequadas, para que não sejam introduzidas falhas na peça. Novos conceitos de lubrificação e refrigeração, para o processo de retificação, estão sendo pesquisados, de forma a diminuir os custos e os danos ambientais causados pelos fluidos de corte. Nesse trabalho, é analisada a influência das técnicas de mínima quantidade de lubrificante (MQL), refrigeração otimizada e refrigeração convencional, com diferentes vazões e velocidade de aplicação do fluido de corte, na qualidade das peças produzidas com aço ABNT 4340 endurecido, no processo de retificação cilíndrica externa de mergulho com a utilização de rebolos de CBN. O Aço ABNT 4340 apresenta várias aplicações industriais, sendo considerado de uso aeronáutico devido, sua alta resistência mecânica sem aumentar o peso dos componentes que o utilizam. A análise da qualidade das peças foi realizada com a verficação das rugosidades e com a análise de microscopias eletrônicas de varredura. Verificou-se, ainda, a força tangencial de corte. em relação às diferentes formas de aplicação do fluido de corte, notou-se o melhor desempenho da aplicação otimizada, para maiores velocidades, mostrando a eficiência do bocal utilizado. O processo otimizado e o processo MQL foram capazes de manter a integridade superficial das peças produzidas. Exceção somente para a condição MQL com vazão de fluido de corte de 40ml/h, que produziu trincas e queima superficial. Rebolos com baixa concentração de CBN, conseqüentemente mais baratos, proporcionaram bons resultados, quando associados com técnicas mais eficientes de aplicação de fluido de corte apresentando desgaste reduzido.

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.

Carotenoids Are Effective Inhibitors Of In Vitro Hemolysis Of Human Erythrocytes, As Determined By A Practical And Optimized Cellular Antioxidant Assay.

β-Carotene, zeaxanthin, lutein, β-cryptoxanthin, and lycopene are liposoluble pigments widely distributed in vegetables and fruits and, after ingestion, these compounds are usually detected in human blood plasma. In this study, we evaluated their potential to inhibit hemolysis of human erythrocytes, as mediated by the toxicity of peroxyl radicals (ROO•). Thus, 2,2'-azobis (2-methylpropionamidine) dihydrochloride (AAPH) was used as ROO• generator and the hemolysis assay was carried out in experimental conditions optimized by response surface methodology, and successfully adapted to microplate assay. The optimized conditions were verified at 30 × 10(6) cells/mL, 17 mM of AAPH for 3 h, at which 48 ± 5% of hemolysis was achieved in freshly isolated erythrocytes. Among the tested carotenoids, lycopene (IC(50) = 0.24 ± 0.05 μM) was the most efficient to prevent the hemolysis, followed by β-carotene (0.32 ± 0.02 μM), lutein (0.38 ± 0.02 μM), and zeaxanthin (0.43 ± 0.02 μM). These carotenoids were at least 5 times more effective than quercetin, trolox, and ascorbic acid (positive controls). β-Cryptoxanthin did not present any erythroprotective effect, but rather induced a hemolytic effect at the highest tested concentration (3 μM). These results suggest that selected carotenoids may have potential to act as important erythroprotective agents by preventing ROO•-induced toxicity in human erythrocytes.

Determination Of Tetrakis(hydroxymethyl)phosphonium Sulfate In Commercial Formulations And Cooling Water By Capillary Electrophoresis With Contactless Conductivity Detection.

A novel capillary electrophoresis method using capacitively coupled contactless conductivity detection is proposed for the determination of the biocide tetrakis(hydroxymethyl)phosphonium sulfate. The feasibility of the electrophoretic separation of this biocide was attributed to the formation of an anionic complex between the biocide and borate ions in the background electrolyte. Evidence of this complex formation was provided by (11) B NMR spectroscopy. A linear relationship (R(2) = 0.9990) between the peak area of the complex and the biocide concentration (50-900 μmol/L) was found. The limit of detection and limit of quantification were 15.0 and 50.1 μmol/L, respectively. The proposed method was applied to the determination of tetrakis(hydroxymethyl)phosphonium sulfate in commercial formulations, and the results were in good agreement with those obtained by the standard iodometric titration method. The method was also evaluated for the analysis of tap water and cooling water samples treated with the biocide. The results of the recovery tests at three concentration levels (300, 400, and 600 μmol/L) varied from 75 to 99%, with a relative standard deviation no higher than 9%.