An efficient strategy for grinding carbon fiber-reinforced silicon carbide composite using minimum quantity lubricant

Abstract

Nowadays, in addition to technical efficiency, the demands for environmentally-friendly machining processes have increased. In this context, development of an efficient strategy for machining of ceramic matrix composites (CMCs) has found crucial importance. CMCs exhibit outstanding properties, especially under harsh and severe conditions. Machining of CMCs, however, suffers from several disadvantages such as substantial costs, high tool wear, poor surface quality and low material removal rate, highlighting the need for optimization and development of efficient machining strategies. Due to extreme hardness of the ceramic matrix, grinding with diamond abrasives is inevitable. The grinding variables and the coolant-lubricant medium play significant roles in reduction of the energy dissipation and improving the finishing quality. Among coolant-lubricant types, minimum quantity lubrication (MQL) technique, which is known as an inexpensive and environmentally-compatible grinding process, can give the best results. In comparison with dry grinding condition, 37.95% reduction in cutting force, 75.93% reduction in surface roughness, and 150% increase in grinding efficiency have been achieved by MQL method. Considering MQL as the optimum coolant-lubricant medium, four machining strategies were developed using desirability function method in which efficiency, quality, and productivity were studied. Moreover, microstructure analysis and also cutting mechanism of grinding process for different types of fiber orientation have been investigated.