There has been a great advance in the grinding process by the development of dressing, lubri-refrigeration and other methods. Nevertheless, all of these advances were gained only for continuous cutting; in other words, the ground workpiece profile remains unchanged. Hence, it becomes necessary to study grinding process using intermittent cutting (grooved workpiece – discontinuous cutting), as little or no knowledge and studies have been developed for this purpose, since there is nothing found in formal literature, except for grooved grinding wheels. During the grinding process, heat generated in the cutting zone is extremely high. Therefore, plenty of cutting fluids are essential to cool not only the workpiece but also the grinding wheel, improving the grinding process. In this paper, grinding trials were performed using a conventional aluminum oxide grinding wheel, testing samples made of AISI 4340 steel quenched and tempered with 2, 6, and 12 grooves. The cylindrical plunge grinding was performed by rotating the workpiece on the grinding wheel. This plunge movement was made at three different speeds. From the obtained results, it can be observed that roughness tended to increase for testing sample with the same number of grooves, as rotation speed increased. Roundness error also tended to increase as the speed rotation process got higher for testing the sample with the same number of grooves. Grinding wheel wear enhanced as rotation speed and number of grooves increased. Power consumed by the grinding machine was inversely proportional to the number of grooves. Subsuperficial microhardness had no significant change. Micrographs reveal an optimal machining operation as there was no significant damage on the machined surface.
Grinding is generally the first choice to provide combination of both superior surface finish and closer dimensional tolerances in a machined component. This process can be employed in manufacturing of continuous and interrupted surfaces. Crankshafts and engine piston rings are examples of ground precision mechanical components having interrupted surfaces. However, the specific literature about grinding of interrupted surfaces is still scarce. In this context, aiming to further contribute to the understanding of the behavior of surface integrity of interrupted surfaces during grinding, this paper presents an experimental investigation of interrupted surfaces ground with white aluminum oxide grinding wheel. Discs of AISI 4340 hardened steel with different number of grooves (2, 6, and 12) on the external surface were tested. Experiments with discs without interrupted surface were also carried out for comparisons. In addition to the number of grooves, three values of infeed rate (0.25, 0.50, and 0.75 mm/min) were used as input parameters. The output parameters investigated were the geometric errors (surface roughness and roundness) of the workpiece material as well as the diametric wheel wear. Analysis of variance (ANOVA) test was performed to verify any statistical difference among the output variables. Results showed that both surface finish and roundness of workpieces with interrupted surfaces were higher than those obtained for continuous surface. These parameters also increased with infeed rate up to 0.50 mm/min, whereas the grinding wheel wear was more sensitive to number of grooves and infeed rate. No thermal damages were observed on the machined workpieces under the conditions investigated.
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