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An investigation on surface grinding of hardened stainless steel S34700 and aluminum alloy AA6061 using minimum quantity of lubrication (MQL) technique

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Abstract

In grinding process, the abrasives plunge and slide against the workpiece during material removal with high specific energy consumption and high grinding zone temperature. To improve process efficiency, lubrication becomes an important requirement of the grinding fluids, along with chip removal and cooling the grinding zone. Grinding fluids have negative influences on the working environment and machining cost in terms of the health of the machine operator, pollution, the possibility of explosion (for oil), filtering, and waste disposal. The use of minimum quantity of lubrication (MQL) with an extremely low consumption of lubricant has been reported as a technologically and environmentally feasible alternative to flood cooling. This paper deals with an investigation of the grindability of hardened stainless steel (UNS S34700) and aluminum alloy AA6061 using dry, MQL, and conventional fluid techniques. One type of SiC and five types of Al2O3 wheels (corundum) as well as vegetable and synthetic ester MQL oils have been tested. The influences of wheel and coolant–lubricant types have been studied on the basis of the grinding forces, surface topography, and surface temperature. Synthetic ester MQL oil was found to give better grinding performance than the vegetable MQL oils. It was argued that the improved performance of the ester oil is caused by the formation of tribo-films on the abrasives and the workpiece, which enhances lubrication by inhibiting metal–abrasive interaction. Also, the grindability of the machined specimens was found to increase substantially by using the MQL grinding process with soft and coarse wheels. In MQL grinding of AA6061 alloy, the use of vegetable oil resulted in the lowest surface roughness, whereas using synthetic ester additives lead to highest surface roughness because of higher chip loading on the grinding wheel and consequently more redeposited material on the workpiece surface.

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Authors and Affiliations

  1. Manufacturing Engineering Group, Islamic Azad University, Dehaghan Branch, Dehaghan, Iran

    Mohammadjafar Hadad & Mostafa Hadi

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  1. Mohammadjafar Hadad
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  2. Mostafa Hadi
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Correspondence to Mohammadjafar Hadad.

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Hadad, M., Hadi, M. An investigation on surface grinding of hardened stainless steel S34700 and aluminum alloy AA6061 using minimum quantity of lubrication (MQL) technique. Int J Adv Manuf Technol 68, 2145–2158 (2013). https://doi.org/10.1007/s00170-013-4830-3

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  • DOI: https://doi.org/10.1007/s00170-013-4830-3

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