Evaluation of cutting fluid application in surface grinding
Introduction
Grinding is an abrasive machining process associated with high heat generation which leads to thermal damages to the workpiece. Therefore, the use of cutting fluid becomes essential to typically improve the process performances. It improves product quality and productivity. These actions of the cutting fluid chiefly depend upon the type of fluid used and their methods of application. The proper use of the grinding fluid can meaningfully improve the machinability and machining quality to a great extent [1]. Therefore, the study of the actions of cutting fluid in various methods of application is important to find the most effective one.
Several application methods of cutting fluid have been studied to improve the cooling and lubrication of the grinding zone. The minimum quantity lubrication (MQL) philosophy has been developed primarily to reduce the cost of production by utilizing the less amount of lubricant [2], [3]. The MQL method, where oil is utilized as cutting fluid is found to improve the lubrication to a considerable extent and the specific energy requirement becomes less compared to the conventional jet cooling method. But the cooling capacity of the tool and work surface is poor. Saberi has found the cooling capacity of MQL is as low as 5% with comparison to cold air [4]. Also, the cleaning of chips arrested between the abrasive grits and cooling ability is poor in MQL [1], [5], [6]. As a result, abrasion and rubbing on the material surface and consequently temperature increases and surface quality and integrity decrease [6], [7]. In terms of surface finish, jet cooling is more proficient than MQL. However, better surface finish is reported by MQL on the hardened material than the soft [8].
Various optimization techniques such as genetic algorithm, ant colony optimization, flower pollination algorithm, etc. have been developed and used to evaluate the optimum grinding conditions. However, authors have only suggested the better method of optimization which gives the closure values to the experimental results [9], [10], [11], [12], [13], [14], [15], [16], [17]. Many researchers have reported that the useful flow rate of the cutting fluid through the grinding zone is critically important to improve the machining quality [18], [19], [20], [21]. The round nozzle has been reported to be more effectual over flat nozzle [22]. Mao et al. have shown the angular position of the nozzle is more effective in improving the process performance than the tangential position and toward the grinding wheel position [23]. Engineer et al. has tested the useful flow rate for two different positions of the nozzle, changing its position both horizontally and vertically. A 26% increase in useful flow rate has been reported when the nozzle is positioned at zero distance from the wheel surface. But positioning the nozzle at the surface of the wheel may give rise to excessive splashing, hence gives rise to an unhealthy working environment and wastage of cutting fluid [24].
Thus, the method of application of coolant has been observed to be a key factor in suggestively improving productivity and product quality. In a recent study, Baumgart has found that at 770 kPa fluid pressure and the speed of the coolant jet at 37% of the wheel speed issued through a flat nozzle can overcome the effect of the boundary-layer airflow around the grinding wheel. But flood cooling by high-pressure jet not only increases the pumping cost but also upsurges the splashing of fluid at the surrounding [22]. Thus, it is required to devise a process to increase the lubrication and cooling by overcoming the consequences of air boundary and without augmenting the pumping cost simultaneously. Numerous techniques of fluid applications such as traditional flood cooling, flood cooling for different nozzle positions, flood cooling at high jet speed and MQL have been studied earlier. But whether they can demand their supremacy over flood cooling at various velocities of fluid jet and flood cooling with optimized angular positions of the scraper board without increasing the production cost at once has not been examined. Between the low flow rate at high velocity and high flow rate at low-velocity jet which one is more effective is correspondingly required to be understood. In the present investigation, all these cutting fluid application methods have been studied. The evaluation analysis has been carried out based on the output variables such as grinding forces, surface roughness, surface texture, wheel loading and chip formation. Finally, the best application method has been suggested.
Section snippets
Experimental setup and methodology
The experiments are performed on a surface grinder machine with wheel velocity of 29.3 m/s, table feed (feed rate) 7.5 m/s and infeed depth 20 µm to evaluate the process performance at diverse grinding conditions. The details of the experimental setup are given in Table 1. Four environmental conditions are selected for this study are given in Table 2. The grinding operations are carried out at the up-grinding mode with 20 µm infeed at each pass. The cross-sectional area, pressure and flow rate
Nozzle flow characteristics
The schematic diagram of the nozzle flow is shown in Fig. 2. The continuity and Bernoulli’s equations are utilized to calculate the velocity and pressure of the jet respectively from a given nozzle. Friction and other minor losses are neglected because of the smaller length of the nozzle. The continuity and Bernoulli’s equations are given as-where, Q, v and a represent the flow rate through the nozzle, the velocity of the fluid (liquid) flow and the area of the nozzle orifice
Grinding forces at various environments
The tangential (Ft) and normal cutting forces (Fn) observed under three different grinding environments of conventional dry, flood cooling and MQL are presented in Fig. 3. Forces in dry conditions are invariably found to be maximum than conventional flood cooling and MQL. A 42% less tangential force (Ft) is required in wet than the dry condition. The obvious reason is the absence of lubricant in a dry environment which increases friction between the wheel and workpiece and the grinding forces
Concluding remarks
Cooling and lubrication under various grinding conditions are presented. Flood cooling has been proved better than the conventional dry and MQL grinding in terms of the cutting force requirement and product quality. The 46% and 7% less average tangential force is required in flood cooling with a nozzle at 42.5° than in dry and MQL grinding respectively.
The speed of jet has been increased without employing the higher capacity pump. But, the flow rate has been found more influential than the
Declaration of Competing Interest
The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.
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