Temperature and energy partition in minimum quantity lubrication-MQL grinding process

Hadad, Mohammadjafar; Tawakoli, Taghi; Sadeghi, M. H.; Sadeghi, Behzad

doi:10.1016/j.ijmachtools.2011.11.010

Cited by 177 publications

(64 citation statements)

References 10 publications

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“…This energy partition is in close to the 65 % value obtained with an AISI 1020 steel workpiece and aluminum oxide wheel by the two matching methods described in the article of Malkin and Guo [33]. The partition ratio (and so the heat flux transmitted to the workpiece) can be evaluated using the following expression [2,3,23]:…”

Section: Experimental Results and Inverse Methods For Determining The supporting

confidence: 75%

“…The optimisation of the grinding process requires good knowledge of both these temperatures. Environmental and economical considerations have led many workers to use the maximum background temperature as a performance indicator in order to validate the effectiveness of innovative cooling solutions, such as MQL [1,2], mist jet cooling [3] and to optimize the grinding hardening process using dry air and liquid nitrogen [4].…”

Section: Introductionmentioning

confidence: 99%

“…In the opposite case, a large number of individual grit sources must be considered. If the thermal load is approximated by a continuous heat source moving at the workpiece velocity, the accurate determination of the heat partition ratio and the thermal balance requires the knowledge of the temperature close to the grinding zone (by thermocouple [1][2][3]8,9], optical fiber [10] or thermography method [11,12]), the actual contact length between the wheel and the workpiece [13], the shape of the heat source (uniform, right angled triangle, scalene triangle [9], parabolic [11]), the effect of contact angle for deep grinding [12,14], the convective heat transfer to the coolant [2,9] and the quantity of heat carried away in the chips. The contact angle is neglected in shallow grinding leading to the assumption of a heat source moving in the plane of the ground surface.…”

Section: Introductionmentioning

confidence: 99%

“…Several thermoelectric methods have been developed to measure the grinding temperature: a standard thermocouple welded to the bottom of a blind hole [2,3,8,9], or a single or double pole grindable thermocouple in the shape of a foil or wire [1,15]. The intrusive method can require many corrections because of systematic errors due to the thermal inertia [16,17], the position of the junction in relation to the ground surface, the presence of the hole [18], the constitutive materials of thermocouples [19] and the contact resistance.…”

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Measurement of grinding temperatures using a foil/workpiece thermocouple

Lefebvre

Lanzetta

Lipiński

et al. 2012

International Journal of Machine Tools and Manufacture

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The high temperature generated in abrasive processes is the main factor responsible for thermal damage to a ground surface. It can be predicted through the thermal balance of the heat fluxes in the process. Such predictions can be experimentally verified using a foil/workpiece thermocouple. To estimate the thermal behaviour of such a sensor, it was dynamically calibrated with a laser beam to measure its frequency response. It was found that the response of the sensor has a time constant dependant on the thermal load and cannot be modelled by a simple first order function. In the calibration conditions used, the sensor is fast enough to measure the surface temperature with a time constant less than 100 microseconds.A high frequency acquisition system allows the signal to be measured at the local grit scale so that the activity of grits and the contact stability between the foil and the workpiece during grinding can be studied. By using the peak temperature and the local cooling after a peak, suitably processed, a local background temperature can be defined. It is shown that this background temperature can be evaluated more accurately by matching the global cooling curve to a finite element solution. The temperatures obtained from the local minima of the local diffusive cooling curve agree better with measured results than a temperature obtained by low pass filtering, which can overestimate the background temperature and so the partition ratio.Keywords: grinding; temperature; thermocouple; dynamic calibration; heat transfer; signal processing Measurement of grinding temperatures using a foil/workpiece thermocouple AbstractThe high temperature generated in abrasive processes is the main factor responsible for thermal damage to a ground surface. It can be predicted through the thermal balance of the heat fluxes in the process. Such predictions can be experimentally verified using a foil/workpiece thermocouple. To estimate the thermal behaviour of such a sensor, it was dynamically calibrated with a laser beam to measure its frequency response. It was found that the response of the sensor has a time constant dependant on the thermal load and cannot be modelled by a simple first order function. In the calibration conditions used, the sensor is fast enough to measure the surface temperature with a time constant less than 100 microseconds.A high frequency acquisition system allows the signal to be measured at the local grit scale so that the activity of grits and the contact stability between the foil and the workpiece during grinding can be studied. By using the peak temperature and the local cooling after a peak, suitably processed, a local background temperature can be defined. It is shown that this background temperature can be evaluated more accurately by matching the global cooling curve to a finite element solution. The temperatures obtained from the local minima of the local diffusive cooling curve agree better with measured results than a temperature obtained by low pass filtering, which can overestimate...

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Section: Experimental Results and Inverse Methods For Determining The supporting

confidence: 75%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Measurement of grinding temperatures using a foil/workpiece thermocouple

Lefebvre

Lanzetta

Lipiński

et al. 2012

International Journal of Machine Tools and Manufacture

View full text Add to dashboard Cite

show abstract

“…Although the amount may vary greatly depending on the materials, processes and the tools as some materials are naturally more lubricant than others, some processes are better able to get the fluid to the right place, and bigger tools need more lubricant than smaller ones [3]. MQL has been proven to be effective in terms of tool wear for various machining like grinding [4,5], milling [6,7] turning [8,9] and many more. MQL has larger scope to be applied in mini to micromachining as well due to the requirement of less heat removal rate and effective chip removal [3].…”

Section: Introductionmentioning

confidence: 99%

Minimum Quantity Lubrication (MQL) and its Effect on Tool Wear During Miniature Drilling :an Experimental Study

Mohamad

Bahar

2016

IJEMM

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Miniature drilling is widely used in industries including electronics and reconstructive surgeries to create small sized holes. Chip removal and effective supply of coolant are the two limiting factors that make the process more complex compared to other meso scale machining processes and also contribute to the tool wear. The tool wear in the process is mainly caused by the interaction, motion and chip production between the tool and work piece. Uniform supply of coolant must be ensured to reach the drilled cavity to keep the tool wear to a minimal level. This study includes experimental investigation of the tool condition after applying Minimum Quantity Lubrication (MQL) system as a greener approach as the name indicates. The tool condition with MQL has also been compared with dry and flood cooling. Two different types of drill bit materials (High Speed Steel and Carbide) have been tested under same experimental condition to drill through Aluminum Alloy 6061 and it has been found that overall performance in terms of tool condition after applying MQL was better compared to the other two methods. The overall wear propagation area was measured for both the conditions. It was seen, the wear propagation covered minimal area with MQL while for flood and dry condition wear was spread over a bigger area on flank.

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An oil‐on‐water minimum quantity lubrication technology for high‐quality grinding of carbon fiber reinforced thermoplastic composites

Li,

Zhao,

Yan

et al. 2024

Polymer Composites

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Carbon fiber reinforced thermoplastic (CFRTP) composites, known for their excellent mechanical properties and environmental sustainability, are highly sought‐after in aerospace, energy, and many other fields. Grinding could be used to realize the high‐accuracy and low‐damage machining of CFRTP components. However, due to the temperature sensitivity and water absorption of CFRTP, dry and flood lubrication grinding could cause thermal damage and hygrothermal aging, respectively. In addition, these methods could lead to dust and excessive cutting fluids harmful to the environment. Addressing these bottlenecks, this study is the first to propose using oil‐on‐water minimum quantity lubrication (OoW‐MQL) to grind CFRTP. Experiments including various lubricating conditions and grinding parameters were performed to investigate the grinding performance. Experimental results showed that OoW‐MQL with the oil–water proportion of 1:1 outperformed the other lubricating conditions, achieving the best surface quality with the lowest grinding forces and temperatures. The optimal oil–water proportion remained almost unchanged under different grinding parameters. Furthermore, importance analysis using the extreme gradient boosting (XGBoost) algorithm demonstrated that oil–water proportion was the most critical factor affecting surface roughness. This study proves the feasibility of OoW‐MQL and provides technical guidance for high‐quality grinding of CFRTP.Highlights Oil‐on‐water minimum quantity lubrication (OoW‐MQL) was proposed to grind carbon fiber reinforced thermoplastic (CFRTP) composites. The experimental results of grinding forces, grinding temperatures, surface roughness and surface morphologies were analyzed, which proved that OoW‐MQL with oil–water proportion (1,1) had outstanding lubricating and cooling capability. The effect of grinding parameters on the optimal oil–water proportion was proved to be negligible through comparative tests under grinding parameters of high force and high temperature. Quantitative analysis using the extreme gradient boosting (XGBoost) algorithm identified the oil–water proportion as the most critical factor influencing surface roughness.

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Temperature and energy partition in minimum quantity lubrication-MQL grinding process

Cited by 177 publications

References 10 publications

Measurement of grinding temperatures using a foil/workpiece thermocouple

Measurement of grinding temperatures using a foil/workpiece thermocouple

Minimum Quantity Lubrication (MQL) and its Effect on Tool Wear During Miniature Drilling :an Experimental Study

An oil‐on‐water minimum quantity lubrication technology for high‐quality grinding of carbon fiber reinforced thermoplastic composites

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