Improvement of steel alloys using indirect cooling grinding (I.C.G.)

Abstract

Appropriate choice of machining conditions contributes directly to improved performance of the machining process. Cooling and lubricating the grinding surface in the machining process has been done using different methods, but each method has its own disadvantages. A new cooling system is proposed in this research to improve the surface roughness in flat-surface grinding. The workpiece is cooled using a mixture of water and antifreeze as a coolant, without directly contacting the cutting tool. The temperature of the workpiece surface remains fixed, and grinding of the workpiece is performed. This novel method has several benefits including no oxidation of workpiece and tool surfaces, no surface hardening from rapid cooling, no chip addition to the coolant, and extended grinding capabilities without replacement. The proposed methodology was tested on four steel alloys, including hot-worked and cold-worked steel, as well as two improved alloys. The tests involved changing various parameters such as the depth of cut, surface temperature, and coolant flow-rate, to analyze how they affected surface roughness. According to the results, the proposed method was remarkably efficient for low-chromium steel alloys. The best surface roughness was obtained using the indirect cooling system for the 1.1191 steel alloy (an improved steel alloy). In general, better results (lower roughness at higher cutting depth) were achieved at higher coolant flow-rates.