Improvement of Lubrication and Cooling in Grinding by Effective Controlling of Air Boundary

Sujit Majumdar

doi:10.11648/j.ijimse.20170206.12

Abstract

The presence of air around a rotating grinding wheel impedes the effective entry of coolant into grinding zone. Therefore, a proficient method is required to minimize this air boundary before the impingement of fluid-jet into the grinding zone. This paper is an experimental study for finding the better effective method of controlling the air boundary around the wheel. Further, two different techniques of suppressing the air barrier has been studied experimentally and statistically towards improving the cutting fluid action in grinding. Fuzzy models are developed to interpret the relationship between the variables and responses. Experiments are conducted on a horizontal surface grinding machine with the application of scraper board and pneumatic barrier separately behind the flood cooling nozzle. The surface roughness and other mechanical properties of these two methods and traditional flood cooling method are compared. The experimental results specified that the tangential force and the requirement of specific energy are reduced by maximum 25% and 20% respectively by the scraper board (SB) with the comparison to the pneumatic barrier (PnB) method for achieving the equivalent surface quality when tested by positioning them at 60° location from grinding zone. Hence, use of scraper board at close proximity to grinding zone is recommended.

Highlights

In the process of grinding, improper entry of coolant into the grinding zone leads to the increase of surface roughness of the finished product, surface burn, residual stress, surface and subsurface crack, wheel loading, etc. [1,2,3]
Which method is more effective in increasing lubrication and cooling into the grinding zone is determined by subsequent experimentation
Experiments and statistical analysis are conducted to compare the performance of the scraper board and pneumatic barrier

Summary

Introduction

In the process of grinding, improper entry of coolant into the grinding zone leads to the increase of surface roughness of the finished product, surface burn, residual stress, surface and subsurface crack, wheel loading, etc. [1,2,3]. The pressure of the air layer around the grinding wheel becomes stronger with the increase of wheel speed [6]. The air barrier is even at low speed does not allow the entry of fluid properly through the contact area. Depletion of this re-circulating air from around the grinding zone may be helpful before impingement of fluid into the contact zone of the wheel and workpiece. The more useful method by which the suppression of this rotating air is possible more effectively is required to be examined so that the strategy of issuing fluid jet into the grinding zone can be made

Methods

Results

Conclusion