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Novel performance assessment of interrupted grinding process using aluminum oxide wheel with resinoid bond

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Abstract

The grinding of interrupted geometries, such as keyways, holes, lubrication channels and crankshafts, bearings, helical drills, sharpening, and gear hobbing process for pre-toothing, presents technical difficulties such as decrease in surface quality and an increase in costs, when compared to continuous grinding process. This work aims to study further findings about interrupted cylindrical grinding process of AISI 4340 steel, with the application of resinoid aluminum oxide grinding wheel and conventional application of MWF. In a novel and innovative way, this work analyzed the wheel wear cost at 3 different feed rates (0.25, 0.50, and 0.75 mm/min) for continuous workpieces and interrupted workpieces with 2, 6, and 12 grooves. In addition, surface roughness, roundness deviation, grinding power, tangential force, microstructural analysis, diametrical wear, and G ratio were also evaluated. In conclusion to the results obtained, the average values of surface roughness Ra and Rz increased with the severity of the process (feed rate and number of grooves). For feed rates varying from 0.25 to 0.75 mm/min, mean values of 0.51 to 1.10 μm (Ra) and 4.52 to 10.99 μm (Rz) were obtained for the condition with 12 interruptions, indicating an increase in the order of 75 to 114% compared to without interrupted workpiece. The quick wear of the wheel, obtained for an average diametrical wheel wear of 5.79 μm for workpiece with 12 interruptions in 0.75 mm/min, produced higher surface roughness values. Variations of more than 80% in roundness deviation were obtained during grinding at feed rates of 0.75 mm/min due to mechanical shocks during material removal process, being observed in force variations from 50 to 700 N. The cost analysis of grinding wheel wear showed the waste of abrasive material for grinding process with interrupted geometries. For all tests, the tool cost for low feed rate (0.25 mm/min) did not suffer great variations. For feed rates of 0.50 and 0.75 mm/min, the cost of tool wear was higher. The condition with the highest percentage increase in cost was recorded for grinding process with workpiece of 12 grooves and feed rate of 0.75 mm/min, generating an increase of up to 1720% in the tool cost. Converting into monetary values, the wheel cost is of $ 12.62 per 1000-piece batch.

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Acknowledgments

The authors are thankful to the Coordination for the Improvement of Higher Level Education Personnel (CAPES), National Council for Scientific and Technological Development (CNPq), and the São Paulo Research Foundation (FAPESP - processes 2013/00551-7, 2015/09197-7 and 2018/22661-2) for support.

The authors also are thankful to companies Nikkon Ferramentas de Corte Ltda - Saint Gobain Group for supplying the grinding wheel and Quimatic Tapmatic Ltda. for the donation of MWF.

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Authors and Affiliations

  1. Department of Control and Industrial Process, Federal Institute of Paraná, Jacarezinho Campus, Jacarezinho, Paraná, Brazil

    Fernando Sabino Fonteque Ribeiro & Eduardo Carlos Bianchi

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

    José Claudio Lopes, Rafael Lemes Rodriguez, Luiz Eduardo de Angelo Sanchez, Hamilton José de Mello & Paulo Roberto de Aguiar

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  1. Fernando Sabino Fonteque Ribeiro
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  2. José Claudio Lopes
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  4. Luiz Eduardo de Angelo Sanchez
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Contributions

Fernando Sabino Fonteque Ribeiro: Writing, original draft; writing, review and editing; visualization; conceptualization; formal analysis; investigation; validation.

José Claudio Lopes: Writing, original draft; resources; conceptualization; methodology; project administration.

Rafael Lemes Rodriguez: Writing, original draft; writing, review and editing; visualization; conceptualization; formal analysis; investigation; validation.

Luiz Eduardo de Angelo Sanchez: Writing, review and editing; conceptualization; supervision.

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.

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Correspondence to Eduardo Carlos Bianchi.

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Ribeiro, F.S.F., Lopes, J.C., Rodriguez, R.L. et al. Novel performance assessment of interrupted grinding process using aluminum oxide wheel with resinoid bond. Int J Adv Manuf Technol 117, 2701–2713 (2021). https://doi.org/10.1007/s00170-021-07757-1

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