Evaluation of cutting fluid application in surface grinding

Abstract

The application of cutting fluid performs a significant role in improving the grinding efficiency. It also ensures the considerable improvement of workpiece quality by reducing the friction coefficient between the wheel and workpiece. The present study is aimed carefully to evaluate the various fluid application methods towards improving grinding performance. Five various techniques of fluid application such as traditional flood cooling, flood cooling at different angular locations of the nozzle, flood cooling in the presence of scraper board (SB) at distinct angular positions, application of fluid at different velocities and pressures through an indigenously made nozzle, and minimum quantity lubrication (MQL) have been typically employed. The techniques are evaluated by assessing the output variables such as grinding forces, surface roughness, surface texture, wheel loading and chip formation. The results confirm that the technique of using the scraper board proximate to the grinding zone can appreciably reduce the grinding force, wheel loading and produces favourable chips and surface texture than other methods of application of the fluid. In particular, positioning scraper board at 57.5° along with the Nozzle at 42.5° reduces the tangential force by 48%, 18%, 12%, compared to dry grinding, MQL and grinding by positioning nozzle at 42.5° respectively. However, the ground surface roughness in MQL succeeds in other methods of application. The findings also reveal that the increase in the fluid flow rate is more important than the velocity towards improving productivity and product quality.