Abstract
The current work presents a study of alternative methods of cooling-lubrication for the external plunge grinding of advanced ceramics using diamond wheels. These two alternative methods, which are intended to reduce cutting fluid expenses, are commonly referred to as the optimized cooling-lubrication method and minimal quantity of lubrication (MQL). The techniques were evaluated by process monitoring and by the assessment of output variables such as tangential cutting force, G ratio, roundness errors, surface roughness, microstructure and residual stresses measured by X-ray diffraction. The obtained results showed that the two proposed techniques can replace the conventional cooling-lubrication method, i.e., flood coolant. In particular, optimized cooling-lubrication method reduced wheel wear and produced workpieces with the best geometric and dimensional finishes, while MQL significantly reduced the amount of fluid employed in the process without harming the workpiece quality.
Highlights
Just as in the processing of metallic materials, grinding of ceramics is usually performed with the aid of cutting fluids
Given the information presented previously, the present study aims to evaluate two alternatives to conventional cooling-lubrication in grinding of advanced ceramics: optimized cooling-lubrication and minimal quantity of lubrication (MQL)
MQL shows the highest values; it is interesting to observe that the magnitude of the cutting force for this method remained more uniform
Summary
Just as in the processing of metallic materials, grinding of ceramics is usually performed with the aid of cutting fluids. Cutting fluids are used to provide lubrication, cooling, chip removal and reduction of operational costs, i.e., power and tools. They improve the machining quality, cutting fluids are directly related to high processing costs[1,2]. According to Astakhov[3], the costs related to cutting fluids, including the product price and the additional expenses related to maintenance and disposal, can be as large as approximately 17% of the total production cost. Besides these economic concerns, cutting fluids may represent potential environmental risks due to their pollutant nature
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