An investigation on surface grinding of AISI 4140 hardened steel using minimum quantity lubrication-MQL technique

Abstract

In dry grinding, as there is no coolant lubricant to transfer the heat from the contact zone, generation of surface damages are not preventable. Promising alternatives to conventional flood coolant applications are also Minimum Quantity Lubricant (MQL) or Near Dry Machining (NDM) or Semi Dry Machining (SDM). As the name implies, MQL machining uses a very small quantity of lubricant delivered precisely to the cutting zone. Often the quantity used is so small that no lubricant is recovered from the parts. Any remaining lubricant may form a film that protects the parts from oxidation or the lubricant may vaporize completely due to high temperatures of the cutting zone. A number of studies have shown that MQL grinding can show satisfactory performance in practical grinding processes. However, there has been little investigation of cutting fluids to be used in MQL grinding. In this study, several grinding fluids, including mineral, vegetable and synthetic esters oil, are compared on the basis of the grinding forces and surface quality properties that would be suitable for MQL grinding applications, to develop a multifunctional fluid having the MQL results such as cooling, lubrication and high ecological and environmental safety performances. The grinding performance of fluids is also evaluated in dry and conventional fluid grinding techniques.

State in the art of cooling and lubrication of the machining zone in grinding processes

“…8. Widok sposobu doprowadzenia mgły olejowej metodą MQL w procesie szlifowania [19] Jak sama nazwa wskazuje, obróbka MQL charakteryzuje się bardzo małą ilością PCS biorącą udział w procesie obróbki (wydatek rzędu 7,2-97,2 ml/h, blisko 1000 razy mniej niż przy konwencjonalnej metodzie zalewowej), która dostarczana jest precyzyjnie do strefy kontaktu CPS z powierzchnią obrabianą [27]. Wióry powstałe podczas szlifowania są praktycznie suche, a taki mechanizm i precyzja tej metody skutecznie redukują wydatek PCS, i co się z tym wiąże, koszty produkcji.…”

Surface Integrity Characterization of Hardened AISI 4340 Steel in Grinding Process with Biodegradable Formulations of Cutting Fluids

“…Lubricants are widely used in all sectors of industry for cooling and lubricating the tool and work-piece interface in order to enhance machinability, as well as flushing the debris originated on the abrasive process 1,2 . Despite the great importance of the use of cutting fluids in machining processes, this use also brings serious disadvantages, such as ecological and environmental problems, leading research works in the last decades to reduce the use of synthetic lubricants 2,3 .…”

“…Despite the great importance of the use of cutting fluids in machining processes, this use also brings serious disadvantages, such as ecological and environmental problems, leading research works in the last decades to reduce the use of synthetic lubricants 2,3 . Recently, biodegradable lubricants have been gradually replacing the synthetic ones.…”

Impact of Compressed Air Pressure on Geometric Structure of Aisi 1045 Steel Surface After Turning With the Use of MQCL Method

“…approx. 1000 times less than when using deluge cooling) [14,18]. Therefore, the consumption of oil and emulsion as well as costs related to their use are significantly reduced.…”