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Mechanical and thermal effects of abrasive cut-off applied in low and medium carbon steels using aluminum oxide cutting disc

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Abstract

Abrasive cutting is broadly applied to obtain structural and electromechanical parts for the industry, as well as metallographic specimens for research laboratories. However, the literature about this process is still scarce, making further studies necessary. Usually, the final quality of the obtained products plays a minor role in comparison to the costs associated with tool wear. In this context, an experimental investigation of the abrasive cut-off operation of low and medium carbon steels, using aluminum oxide discs with different feed rates (2.0, 3.4, and 4.6 mm/s), is reported. The cutting power, disc wear, and process temperature were monitored and comprehensively evaluated. Besides, a computational simulation was developed for temperature prediction and the results were compared with the experimental data. The disc surface was assessed through confocal and scanning electron microscopies, and the chips were analyzed with scanning electron microscopy and energy dispersive spectroscopy. Contrary to what was expected, an increase of 130% in feed rate led to a decrease of approximately 57% in maximum temperature, and 84% in diametrical wheel wear, improving process efficiency. On the other hand, the consumed cutting power increased by up to 127%. The proposed simulation model presented a high correlation with the experimental data and can be applied to predict and prevent thermal damages to the parts.

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Acknowledgments

The authors thank the Norton Company, from Saint Gobain Group, for providing the discs.

Funding

The study was financially supported by the São Paulo Research Foundation (FAPESP – process 2018/22661-2), Coordination for the Improvement of Higher Level Education Personnel (CAPES), and National Council for Scientific and Technological Development (CNPq).

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Authors and Affiliations

  1. Department of Mechanical Engineering, São Paulo State University “Júlio de Mesquita Filho”, Bauru campus, Bauru, São Paulo, 17033-360, Brazil

    José Claudio Lopes, Rafael Liberatti Javaroni, Mateus Vinicius Garcia, Vicente Luiz Scalon, Luiz Eduardo de Angelo Sanchez, Hamilton José de Mello & Eduardo Carlos Bianchi

  2. Department of Control and Industrial Processes, Federal Institute of Education Science and Technology of Parana, Jacarezinho campus, Jacarezinho, Paraná, Brazil

    Fernando Sabino Fonteque Ribeiro

  3. Department of Mechanical Engineering, Federal University of São Carlos, Rod. Washington Luís km 235, São Carlos, SP, 13565-905, Brazil

    Carlos Eiji Hirata Ventura

  4. Department of Electrical Engineering, São Paulo State University “Júlio de Mesquita Filho”, Bauru campus, Bauru, São Paulo, Brazil

    Paulo Roberto Aguiar

Authors
  1. José Claudio Lopes
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  2. Fernando Sabino Fonteque Ribeiro
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  3. Rafael Liberatti Javaroni
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  6. Vicente Luiz Scalon
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  7. Luiz Eduardo de Angelo Sanchez
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  8. Hamilton José de Mello
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  10. Eduardo Carlos Bianchi
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Correspondence to Eduardo Carlos Bianchi.

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Lopes, J.C., Ribeiro, F.S.F., Javaroni, R.L. et al. Mechanical and thermal effects of abrasive cut-off applied in low and medium carbon steels using aluminum oxide cutting disc. Int J Adv Manuf Technol 109, 1319–1331 (2020). https://doi.org/10.1007/s00170-020-05753-5

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