Abstract
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
Highlights
Grinding is considered one of the most complex machining processes due to the large number of variables it involves
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 nish, at low costs, and without damaging the environment. The latter requirement can be achieved by recycling cutting uids, which is a costly solution, or by drastically reducing the amount of cutting uids employed in the grinding process
Bianchi and de Aguiar: Grinding of hardened steels using optimized cooling power (Pc) consumed by the motor driving the axletree of the grinding wheel, which was obtained by monitoring the values of voltage and electric current of this electric motor
Summary
Grinding is considered one of the most complex machining processes due to the large number of variables it involves. A circular nozzle was used, as proposed by Webster [2], with a circular Ø4mm beak to distribute the cutting uid at a velocity approximately equal to that of the grinding wheel’s peripheral velocity (Vs) This velocity is necessary to enable the cutting uid to overcome the air barrier generated by the high rotation of the grinding wheel and penetrate the region of the workpiece-tool interface without the loss of speed and pressure [3], favoring cooling in the process. The study reported here, involving cylindrical plunge grinding, analyzed the in uence of the plunge velocity, the performance of the CBN grinding wheel, and the in uence of different cutting uids using optimized lubrication and cooling Output variables such as surface nishing, roundness errors, diametral grinding wheel wear, tangential cutting force, acoustic emission, residual stresses were analyzed, as was the microstructure of nished components
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