Plunge cylindrical grinding with the minimum quantity lubrication coolant technique assisted with wheel cleaning system

Abstract

MQL technique is considered as a cleaner machining compared to the conventional coolant delivery one, thereby ensuring environmental sustainability and economic benefits. However, one of problems commonly reported when using the MQL technique is the wheel clogging phenomenon as a result of the inefficient chip removal from the cutting zone, then the chips lodge inside the pores of the grinding wheel, adversely affecting the quality and the finishing of the final product. In this context, this study was carried out to evaluate the performance of the minimum quantity lubrication coolant technique assisted with a wheel cleaning jet (MQL + WCJ) in plunge grinding of hardened steel. This cooling-lubrication technique was tested using the following flow rates: 30, 60, and 120 ml/h. Comparative tests were also carried out with the conventional coolant technique, as well as with the traditional MQL technique (without the wheel cleaning jet). The output variables used to assess the efficiency of the MQL + WCJ technique are roughness, roundness, workpiece microhardness, grinding wheel wear, and power consumption. The results showed that the machining with the MQL + WCJ technique outperformed the traditional MQL technique in all the output parameters investigated. Also, the efficiency of the MQL + WCJ technique increased with flow rate, thereby being an alternative coolant delivery technique in grinding due to cleaner environment, more sustainable and lower consumption of fluid compared to conventional coolant one. No thermal damages and cracks on the machined surface and sub-surfaces were observed after grinding AISI 4340 steel, irrespective of the technique.

Modern Approach to Delivery Coolants, Lubricants and Antiadhesives in the Environmentally Friendly Grinding Processes

“…The air-oil aerosol covers the GWAS and the workpiece surface, cooling down and applying a lubricating film of oil on the workpiece surface. This allows to reduce the friction force between the abrasive grains and the workpiece surface as well as to reduce the grinding force F c and the amount of heat generated [75][76][77][78][79][80][81][82][83][84][85][86][87][88][89][90][91][92].…”

Simulation Studies on Centrifugal MQL-CCA Method of Applying Coolant during Internal Cylindrical Grinding Process

“…At the same time, these works took into account the possibility of minimising the amount of coolants delivered. In this context, the most frequent description in the literature is the minimum quantity lubrication (MQL) method, the possibilities of which have been analysed in relation to machining [15,16] as well as with respect to the grinding process in general [17][18][19][20][21][22][23][24][25][26][27][28]. Most often, researchers focus on surface grinding process [29][30][31][32], but the possibilities of the MQL method in the grinding of hard-to-cut materials have also been considered [33][34][35][36].…”

Application of minimum quantity lubrication with addition of water in the grinding of alumina

“…Moreover, the material used (AISI 1020) is a soft steel and does not influence wheel wear. Reliable results using this method were obtained in [19][20][21][22].…”

“…With this configuration, surface roughness, roundness deviation, and wheel wear presented lower values than those obtained for grinding with conventional flood cooling. Bianchi et al [20] carried out experiments with the application of the same technique, but with an aluminum oxide grinding wheel. The obtained results also demonstrated that the application of MQL combined with a cleaning jet corresponds to a viable alternative to the use of conventional flood cooling.…”