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Effect of grinding with different CBN grains applied to austempered ductile iron linked to quality and industrial cost

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Abstract

The grinding process consists of an essential stage of manufacture that is justified by the process’ ability to guarantee precise dimensions and provide an excellent surface finish. In the present study, two grinding wheels of cubic boron nitride (CBN) abrasive grains with different friability (GL and GS) were used to perform the cylindrical grinding of the austempered ductile iron (ADI). This work compared the individual performance of each wheel, with CBN GL being of low friability and CBN GS of high. During machining with three feed rates (0.5, 1.0, and 1.5 mm/min), the conventional lubri-refrigeration method was used. In the workpieces analyzed, the tests of surface roughness, roundness deviation, specific energy, G-ratio, acoustic emission, cost analysis, microhardness, confocal microscopy, and optical microscopy were applied. The tests showed that, in almost all the output parameters, the best results obtained were using the CBN GL wheel with less friability. However, in the analysis of acoustic emission and specific energy, the results presented that the GS wheel obtained the best results; as it is a more friable tool, the efforts applied during the grinding of the GS wheel are less. Also, the microstructure analyses showed that both wheels were able to carry out the process without causing changes in the workpieces’ mechanical properties. The cost analysis of the inputs showed that the increase in the feed rate produces the lowest cost.

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Acknowledgements

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

Funding

The authors thank São Paulo Research Foundation (FAPESP) processes 2018/22661-2 and 2019/24933-2, CAPES (Coordination for the Improvement of Higher Level Education Personnel), and CNPq (National Council for Scientific and Technological Development) for their financial support to 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, São Paulo, Brazil

    Rodrigo Ráfaga de Souza, Douglas Lyra de Moraes, Mateus Vinicius Garcia, José Claudio Lopes, Hamilton José de Mello, Luiz Eduardo De Angelo Sanchez & Eduardo Carlos Bianchi

  2. Department of Control and Industrial Processes, Federal Institute of Paraná, Jacarezinho Campus, Jacarezinho, Paraná, Brazil

    Fernando Sabino Fonteque Ribeiro

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

    Paulo Roberto Aguiar

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  1. Rodrigo Ráfaga de Souza
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Contributions

Rodrigo Ráfaga de Souza: writing - original draft; writing - review and editing; visualization; conceptualization; formal analysis; investigation; validation.

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

Mateus Vinicius Garcia: writing - original draft; investigation; data curation; formal analysis.

José Claudio Lopes: writing - original draft; resources; conceptualization; methodology; project administration.

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

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

Luiz Eduardo de Angelo Sanchez: writing - review and editing; conceptualization; supervision.

Paulo Roberto Aguiar: software; supervision.

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

Corresponding author

Correspondence to José Claudio Lopes.

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de Souza, R.R., de Moraes, D.L., Garcia, M.V. et al. Effect of grinding with different CBN grains applied to austempered ductile iron linked to quality and industrial cost. Int J Adv Manuf Technol 113, 807–820 (2021). https://doi.org/10.1007/s00170-021-06647-w

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