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Advances in precision manufacturing towards eco-friendly grinding process by applying MQL with cold air compared with cooled wheel cleaning jet

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Abstract

With the evolution of the sustainable industry, the grinding process seeks to follow the requirements to continue to be highly employed when precision and low-dimensional tolerances are required in the workpieces. In this way, the cutting fluids used in the process, which are essential for a good surface finish, are the main impasse to ensure that the process becomes eco-friendly. Therefore, a widespread lubri-refrigeration method in the industry is the flood technique, which uses a lot of fluid to reduce the high temperatures generated during grinding. However, the use of the flood method generates many undesirable residues that affect the machine operator, the environment, and production costs. Thus, several alternatives have emerged to address these problems, for example, the minimum quantity of lubricant (MQL), the wheel cleaning jet system (WCJ), and the application of cooled air (CA). Therefore, this work sought to analyze the combination of these systems (MQL+CA, MQL+WCJ, and MQL) in the grinding of AISI 4340 steel using an aluminum oxide wheel (Al2O3) and to verify their performance compared with the flood method, in addition to employing a new method known as cooled wheel cleaning jet (CWCJ). Therefore, the tests of surface roughness (Ra and Rz), roundness error, diametrical wheel wear, G ratio, grinding power, tangential cutting force, and microhardness were performed, and optical, confocal, and scanning electron microscopy also were analyzed. Thus, the results that came closest to the flood method in all tests were achieved by systems that applied grinding wheel cleaning (MQL + WCJ and MQL + CWCJ), being that in the diametrical wheel wear and G ratio the MQL + CWCJ even managed to surpass it. Besides, the MQL+CA union showed better values when compared with MQL without any assistance. Thus, applying MQL with helper systems, mainly CWCJ, contributed to a more economical, efficient, and sustainable grinding process.

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Acknowledgments

The authors also thank companies Nikkon Ferramentas de Corte Ltda—Saint Gobain Group for providing the grinding wheel, ITW Chemical Products for the donation the cutting fluids, and the authors thank everyone by support to the research and opportunity for scientific and technological development.

Funding

The authors thank São Paulo Research Foundation (FAPESP) processes 2019/24933-2 and 2020/06038-3, CAPES (Coordination for the Improvement of Higher Level Education Personnel), and CNPq (National Council for Scientific and Technological Development) for their financial support of this research.

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Authors and Affiliations

  1. Department of Mechanical Engineering, São Paulo State University “Júlio de Mesquita Filho”, Bauru campus, Bauru, Sao Paulo, Brazil

    Douglas Lyra de Moraes, José Claudio Lopes, Bruno Vicente Andrioli, Guilherme Bressan Moretti, Andrigo Elisiario da Silva, Fernando Sabino Fonteque Ribeiro, Paulo Roberto de Aguiar & Eduardo Carlos Bianchi

  2. School of Science, São Paulo State University “Júlio de Mesquita Filho”, Bauru campus, Bauru, Sao Paulo, Brazil

    Jean Machado Maciel da Silva & Eduardo Carlos Bianchi

  3. Federal University of Amazonas, Manaus campus, Manaus, Amazonas, Brazil

    Jean Machado Maciel da Silva

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  1. Douglas Lyra de Moraes
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  2. José Claudio Lopes
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Contributions

Douglas Lyra de Moraes: writing—original draft; writing—review and editing; visualization; conceptualization; formal analysis; investigation; validation.

José Claudio Lopes: writing—original draft; writing—review and editing; visualization; conceptualization; formal analysis; investigation; validation.

Bruno Vicente Andrioli: writing—original draft; writing—review and editing; visualization; conceptualization; formal analysis; investigation; validation.

Guilherme Bressan Moretti: writing—original draft; writing—review and editing; visualization; conceptualization; formal analysis; investigation; validation.

Andrigo Elisiario da Silva: writing—original draft; writing—review and editing; visualization; conceptualization; formal analysis; investigation; validation.

Jean Machado Maciel da Silva: writing—original draft; investigation; data curation; formal analysis.

Fernando Sabino Fonteque Ribeiro: conceptualization; methodology; validation; writing—original draft.

Hamilton José de Mello: conceptualization; methodology; formal analysis; investigation; validation.

Paulo Roberto Aguiar: software; supervision.

Eduardo Carlos Bianchi: funding acquisition; conceptualization; resources; supervision; project administration.

Corresponding author

Correspondence to Douglas Lyra de Moraes.

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de Moraes, D.L., Lopes, J.C., Andrioli, B.V. et al. Advances in precision manufacturing towards eco-friendly grinding process by applying MQL with cold air compared with cooled wheel cleaning jet. Int J Adv Manuf Technol 113, 3329–3342 (2021). https://doi.org/10.1007/s00170-021-06713-3

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