Skip to main content
SpringerLink
Log in

Grinding behavior of VP50IM steel using green and black silicon carbide compared to aluminum oxide wheel under different feed rates

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Technological advances and the development of new products make it increasingly necessary to seek to improve production means to meet the growing demand for equipment and consumer goods. In this sense, the molds enable the large-scale production of complex workpieces and equipment, which could hardly be manufactured through conventional machining. Also, the molds’ surface quality must be high to avoid deviations in the produced workpieces, being achieved through grinding. Thus, this work evaluates the performance of the VP50IM mold steel grinding process using feed rates of 0.25, 0.50, and 0.75 mm/min under the conventional lubrication method, comparing the results obtained with conventional wheels of white aluminum oxide, green silicon carbide, and white aluminum oxide and black silicon carbide grain tool. The comparison was made considering the results of surface roughness (Ra), roundness error, acoustic emission, G-ratio, diametrical wheel wear, tangential grinding force, grinding power, microhardness, microscopies, and grinding costs. The results’ analysis shows an advantage of using the green silicon carbide grinding wheel, which even in the worst scenario (0.75 mm/min) presented 14.83% less wear, 10.81% less acoustic emission, and consumed 10.18% less grinding power in comparison to the black silicon carbide wheel, with even better results when compared to the white aluminum oxide. Meanwhile, grinding with green silicon carbide wheel produced 9.88% lower surface roughness and 4.80% less roundness error in the worst condition when compared to the black silicon carbide tool. The machining costs with green silicon carbide were very close to those observed in the grinding with white aluminum oxide and the black silicon carbide, corroborating the grinding advantage of the VP50IM mold steel with a green silicon carbide wheel.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2.
Fig. 3.
Fig. 4.
Fig. 5.
Fig. 6.
Fig. 7.
Fig. 8.
Fig. 9.
Fig. 10.
Fig. 11.
Fig. 12.

Similar content being viewed by others

Abbreviations

CBN:

Cubic boron nitride

SiC:

Silicon carbide

Al2O3 :

Aluminum oxide

Ra:

Surface roughness

ae :

Cutting depth

Ce :

Energy cost

Cf:

Cutting fluid cost

Cw:

Cutting fluid disposal cost

Cs:

Cost of usable grinding wheel

G:

G-ratio

R:

Approach distance from piece

tso:

Spark out time

HRC:

Hardness Rockwell C

HV:

Hardness Vickers

Vs:

Grinding wheel speed

Vw:

Workpiece speed

Vf:

Feed rate

M:

Grinding labor cost

Nc:

Number of fluid cycle life

Pop:

Oil pump power

Pc:

Cutting power

V:

Volume of removed VP50IM

Vjet:

Fluid flow

r:

Rapid approach rate

References

  1. Li B, Li C, Zhang Y, Wang Y, Jia D, Yang M (2016) Grinding temperature and energy ratio coefficient in MQL grinding of high-temperature nickel-base alloy by using different vegetable oils as base oil. Chin J Aeronaut 29:1084–1095. https://doi.org/10.1016/j.cja.2015.10.012

    Article  Google Scholar 

  2. Alexandre FA, Lopes JC, de Martini FL et al (2020) Depth of dressing optimization in CBN wheels of different friabilities using acoustic emission (AE) technique. Int J Adv Manuf Technol 106:5225–5240. https://doi.org/10.1007/s00170-020-04994-8

    Article  Google Scholar 

  3. Lopes JC, de Martini FL, Garcia MV et al (2020) Performance of austempered ductile iron ( ADI ) grinding using diluted oil in MQL combined with wheel cleaning jet and different CBN grains friability. Int J Adv Manuf Technol 107:1805–1818. https://doi.org/10.1007/s00170-020-05142-y

    Article  Google Scholar 

  4. Daniel DM, Ávila BN, Garcia MV, Lopes JC, Ribeiro FSF, de Mello HJ, de Angelo Sanchez LE, Aguiar PR, Bianchi EC (2020) Grinding comparative between ductile iron and austempered ductile iron under CBN wheel combined to abrasive grains with high and low friability. Int J Adv Manuf Technol 109:2679–2690. https://doi.org/10.1007/s00170-020-05787-9

    Article  Google Scholar 

  5. Julean D (2017) SPH Simulation of single grain action in grinding. In: MATEC Web of Conferences. EDP Sci, p 3006

  6. de Moraes DL, Lopes JC, Andrioli BV, Moretti GB, da Silva AE, da Silva JMM, Ribeiro FSF, de Aguiar PR, Bianchi EC (2021) 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. https://doi.org/10.1007/s00170-021-06713-3

    Article  Google Scholar 

  7. Lopes JC, de Martini FL, Domingues BB et al (2019) Effect of CBN grain friability in hardened steel plunge grinding. Int J Adv Manuf Technol 103:1567–1577. https://doi.org/10.1007/s00170-019-03654-w

    Article  Google Scholar 

  8. Sato BK, Rodriguez RL, Talon AG, Lopes JC, Mello HJ, Aguiar PR, Bianchi EC (2019) Grinding performance of AISI D6 steel using CBN wheel vitrified and resinoid bonded. Int J Adv Manuf Technol 105:2167–2182. https://doi.org/10.1007/s00170-019-04407-5

    Article  Google Scholar 

  9. Klocke F (2009) Manufacturing processes 2: grinding, honing, lapping, 1st edn. Springer-Verlag, Berlin Heidelberg

    Book  Google Scholar 

  10. Javaroni RL, Lopes JC, Garcia MV, Ribeiro FSF, de Angelo Sanchez LE, de Mello HJ, Aguiar PR, Bianchi EC (2020) Grinding hardened steel using MQL associated with cleaning system and cBN wheel. Int J Adv Manuf Technol 107:2065–2080. https://doi.org/10.1007/s00170-020-05169-1

    Article  Google Scholar 

  11. Li H, Yu T, Zhu L, Wang W (2015) Analysis of loads on grinding wheel binder in grinding process: insights from discontinuum-hypothesis-based grinding simulation. Int J Adv Manuf Technol 78:1943–1960

    Article  Google Scholar 

  12. de Martini FL, Lopes JC, Volpato RS et al (2018) Comparative analysis of two CBN grinding wheels performance in nodular cast iron plunge grinding. Int J Adv Manuf Technol 98:237–249. https://doi.org/10.1007/s00170-018-2133-4

    Article  Google Scholar 

  13. Denkena B, Grove T, Bremer I, Behrens L (2016) Design of bronze-bonded grinding wheel properties. CIRP Ann 65:333–336. https://doi.org/10.1016/J.CIRP.2016.04.096

    Article  Google Scholar 

  14. Sato BK, Lopes JC, Diniz AE, Rodrigues AR, de Mello HJ, Sanchez LEA, Aguiar PR, Bianchi EC (2020) Toward sustainable grinding using minimum quantity lubrication technique with diluted oil and simultaneous wheel cleaning. Tribol Int 147:106276. https://doi.org/10.1016/j.triboint.2020.106276

    Article  Google Scholar 

  15. Lopes JC, Fragoso KM, Garcia MV, Ribeiro FSF, Francelin AP, de Angelo Sanchez LE, Rodrigues AR, de Mello HJ, Aguiar PR, Bianchi EC (2019) Behavior of hardened steel grinding using MQL under cold air and MQL CBN wheel cleaning. Int J Adv Manuf Technol 105:4373–4387. https://doi.org/10.1007/s00170-019-04571-8

    Article  Google Scholar 

  16. De Godoy VAA, Diniz AE (2011) Turning of interrupted and continuous hardened steel surfaces using ceramic and CBN cutting tools. J Mater Process Technol 211:1014–1025. https://doi.org/10.1016/j.jmatprotec.2011.01.002

    Article  Google Scholar 

  17. Beranoagirre A, de Lacalle LNL (2013) Grinding of gamma TiAl intermetallic alloys. Proc Eng 63:489–498

    Article  Google Scholar 

  18. Rodriguez RL, Lopes JC, Garcia MV, Tarrento GE, Rodrigues AR, de Ângelo Sanchez LE, de Mello HJ, de Aguiar PR, Bianchi EC (2020) Grinding process applied to workpieces with different geometries interrupted using CBN wheel. Int J Adv Manuf Technol 107:1265–1275. https://doi.org/10.1007/s00170-020-05122-2

    Article  Google Scholar 

  19. Guimarães C, da Silva RB, de Souza RR et al (2019) Evaluation of surface and sub-surface integrities of a mold steel under different grinding conditions. J Braz Soc Mech Sci Eng 41:435

    Article  Google Scholar 

  20. dos Anjos MA, Bianchi EC, de Mello HJ et al (2016) Experimental study of the use of conventional wheels on steel processing VP-50 used in the cylindrical grinding by means of different methods of lubrication and cooling. Matéria (Rio Janeiro) 21:169–184

    Article  Google Scholar 

  21. Wang H, Ning F, Hu Y, Cong W (2018) Surface grinding of CFRP composites using rotary ultrasonic machining: a comparison of workpiece machining orientations. Int J Adv Manuf Technol 95:2917–2930

    Article  Google Scholar 

  22. Rabiei F, Rahimi AR, Hadad MJ, Ashrafijou M (2015) Performance improvement of minimum quantity lubrication (MQL) technique in surface grinding by modeling and optimization. J Clean Prod 86:447–460. https://doi.org/10.1016/j.jclepro.2014.08.045

    Article  Google Scholar 

  23. PLASTICS EUROPE. (2019) PLASTICS-THE FACTS. An analysis of European plastics production, demand and waste data.

  24. Hähnel S, Grunwald T, Bergs T, et al (2020) Vibration-assisted face grinding of mould steel. pp 291–303

  25. Huang W-T, Liu W-S, Tsai J-T, Chou J-H (2017) Multiple quality characteristics of nanofluid/ultrasonic atomization minimum quality lubrication for grinding hardened mold steel. IEEE Trans Autom Sci Eng 15:1065–1077

    Article  Google Scholar 

  26. Ohmori H, Katahira K, Komotori J, Mizutani M (2008) Functionalization of stainless steel surface through mirror-quality finish grinding. CIRP Ann 57:545–549. https://doi.org/10.1016/j.cirp.2008.03.131

    Article  Google Scholar 

  27. PLASTIKE MOJZAB (2018) Optimization of surface roughness in finish milling of AISI P20+ S plastic-mold steel. Optimization 195:200

    Google Scholar 

  28. de Sampaio Alves LOB, Bianchi EC, de Aguiar PR, et al External plunge grinding of the N2711 steel for plastic injection mold with two different techniques of lubrication and cooling

  29. Martínez-Mateo I, Carrión-Vilches FJ, Sanes J, Bermúdez MD (2011) Surface damage of mold steel and its influence on surface roughness of injection molded plastic parts. Wear 271:2512–2516

    Article  Google Scholar 

  30. Rech J, Le Calvez C, Dessoly M (2004) A new approach for the characterization of machinability—application to steels for plastic injection molds. J Mater Process Technol 152:66–70

    Article  Google Scholar 

  31. Park C, Sim A, Ahn S, Kang H, Chun EJ (2019) Influence of laser surface engineering of AISI P20-improved mold steel on wear and corrosion behaviors. Surf Coat Technol 377:124852

    Article  Google Scholar 

  32. Hoseiny H, Caballero FG, M’Saoubi R, Högman B, Weidow J, Andrén HO (2015) The influence of heat treatment on the microstructure and machinability of a prehardened mold steel. Metall Mater Trans A 46:2157–2171

    Article  Google Scholar 

  33. Field M, Kegg R, Buescher S (1980) Computerized cost analysis of grinding operations. CIRP Ann 29:233–237. https://doi.org/10.1016/S0007-8506(07)61328-6

    Article  Google Scholar 

  34. (2020) Electricity prices. https://www.globalpetrolprices.com/electricity_prices/. Accessed 17 Nov 2020

  35. Demirbas E, Kobya M (2017) Operating cost and treatment of metalworking fluid wastewater by chemical coagulation and electrocoagulation processes. Process Saf Environ Prot 105:79–90. https://doi.org/10.1016/j.psep.2016.10.013

    Article  Google Scholar 

  36. Pusavec F, Kramar D, Krajnik P, Kopac J (2010) Transitioning to sustainable production—part II: evaluation of sustainable machining technologies. J Clean Prod 18:1211–1221. https://doi.org/10.1016/j.jclepro.2010.01.015

    Article  Google Scholar 

  37. Wang Z, Zhang T, Yu T, Zhao J (2020) Assessment and optimization of grinding process on AISI 1045 steel in terms of green manufacturing using orthogonal experimental design and grey relational analysis. J Clean Prod 253:119896. https://doi.org/10.1016/j.jclepro.2019.119896

    Article  Google Scholar 

  38. Herman D, Krzos J (2009) Influence of vitrified bond structure on radial wear of cBN grinding wheels. J Mater Process Technol 209:5377–5386

    Article  Google Scholar 

  39. Lee D-E, Hwang I, Valente CMO, et al (2006) Precision manufacturing process monitoring with acoustic emission. In: Condition monitoring and control for intelligent manufacturing. Springer, pp 33–54

  40. Ribeiro FSF, Lopes JC, Garcia MV, de Angelo Sanchez LE, de Mello HJ, de Aguiar PR, Bianchi EC (2020) Grinding assessment of workpieces with different interrupted geometries using aluminum oxide wheel with vitrified bond. Int J Adv Manuf Technol 108:931–941. https://doi.org/10.1007/s00170-020-05500-w

    Article  Google Scholar 

  41. Ribeiro FSF, Lopes JC, Garcia MV, de Moraes DL, da Silva AE, de Angelo Sanchez LE, de Aguiar PR, Bianchi EC (2020) New knowledge about grinding using MQL simultaneous to cooled air and MQL combined to wheel cleaning jet technique. Int J Adv Manuf Technol 109:905–917. https://doi.org/10.1007/s00170-020-05721-z

    Article  Google Scholar 

  42. Ding W, Zhu Y, Zhang L, Xu J, Fu Y, Liu W, Yang C (2015) Stress characteristics and fracture wear of brazed CBN grains in monolayer grinding wheels. Wear 332–333:800–809. https://doi.org/10.1016/j.wear.2014.12.008

    Article  Google Scholar 

  43. Marinescu ID, Rowe WB, Dimitrov B, Ohmori H (2013) Tribology of abrasive machining processes. Elsevier

  44. Guo S, Li C, Zhang Y, Wang Y, Li B, Yang M, Zhang X, Liu G (2017) Experimental evaluation of the lubrication performance of mixtures of castor oil with other vegetable oils in MQL grinding of nickel-based alloy. J Clean Prod 140:1060–1076. https://doi.org/10.1016/J.JCLEPRO.2016.10.073

    Article  Google Scholar 

  45. Ding W-F, Xu J-H, Chen Z-Z, Su HH, Fu YC (2010) Wear behavior and mechanism of single-layer brazed CBN abrasive wheels during creep-feed grinding cast nickel-based superalloy. Int J Adv Manuf Technol 51:541–550. https://doi.org/10.1007/s00170-010-2643-1

    Article  Google Scholar 

  46. Hadad MJJ, Tawakoli T, Sadeghi MHH, Sadeghi B (2012) Temperature and energy partition in minimum quantity lubrication-MQL grinding process. Int J Mach Tools Manuf 54–55:10–17. https://doi.org/10.1016/j.ijmachtools.2011.11.010

    Article  Google Scholar 

  47. de Jesus Oliveira D, Guermandi LG, Bianchi EC et al (2012) Improving minimum quantity lubrication in CBN grinding using compressed air wheel cleaning. J Mater Process Technol 212:2559–2568. https://doi.org/10.1016/j.jmatprotec.2012.05.019

    Article  Google Scholar 

  48. Lopes JC, Ávila BN, de Souza Rodrigues M et al (2021) Grinding comparative analysis between different proportions of water-oil applied to MQL technique and industrial production cost towards a green manufacturing. Int J Adv Manuf Technol 113:1281–1293. https://doi.org/10.1007/s00170-021-06625-2

    Article  Google Scholar 

  49. de Moraes DL, Garcia MV, Lopes JC, Ribeiro FSF, de Angelo Sanchez LE, Foschini CR, de Mello HJ, Aguiar PR, Bianchi EC (2019) Performance of SAE 52100 steel grinding using MQL technique with pure and diluted oil. Int J Adv Manuf Technol 105:4211–4223. https://doi.org/10.1007/s00170-019-04582-5

    Article  Google Scholar 

  50. Lopes JC, Garcia MV, Valentim M, Javaroni RL, Ribeiro FSF, de Angelo Sanchez LE, de Mello HJ, Aguiar PR, Bianchi EC (2019) Grinding performance using variants of the MQL technique: MQL with cooled air and MQL simultaneous to the wheel cleaning jet. Int J Adv Manuf Technol 105:4429–4442. https://doi.org/10.1007/s00170-019-04574-5

    Article  Google Scholar 

Download references

Acknowledgements

Sincere thanks to Villares Metals S.A. for the supply of material and ABRASIPA for the donation and information on abrasive tools used in this research.

Funding

The authors thank the São Paulo Research Foundation (FAPESP) processes 2018/22661-2, 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.

Author information

Authors and Affiliations

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

    Andrigo Elisiario da Silva, José Claudio Lopes, Douglas Lyra de Moraes, Mateus Vinicius Garcia, 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

    Jorge Luiz Cuesta & Paulo Roberto Aguiar

Authors
  1. Andrigo Elisiario da Silva
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Jorge Luiz Cuesta
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. José Claudio Lopes
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Douglas Lyra de Moraes
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Mateus Vinicius Garcia
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Fernando Sabino Fonteque Ribeiro
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Hamilton José de Mello
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Luiz Eduardo De Angelo Sanchez
    View author publications

    You can also search for this author in PubMed Google Scholar

  9. Paulo Roberto Aguiar
    View author publications

    You can also search for this author in PubMed Google Scholar

  10. Eduardo Carlos Bianchi
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

AES: Writing original draft; writing review and editing; visualization; conceptualization; formal analysis; investigation; validation. JLC: Writing original draft; writing review and editing; visualization; conceptualization; formal analysis; investigation; validation. JCL: Writing original draft; resources; conceptualization; methodology; project administration. DLM: Writing original draft; investigation; data curation; formal analysis. MVG: Writing original draft; investigation; data curation; formal analysis. FSFR: Conceptualization; methodology; validation; writing original draft. HJM: Conceptualization; methodology; formal analysis; investigation; validation. LEAS: Writing—review & editing; conceptualization; supervision. PRA: Software; supervision. ECB: Funding acquisition; conceptualization; resources; supervision; project administration.

Corresponding author

Correspondence to Eduardo Carlos Bianchi.

Ethics declarations

Ethics approval

The authors declare that this manuscript was not submitted to more than one journal for simultaneous consideration. Also, the submitted work was original and has not been published elsewhere in any form or language.

Consent to participate/consent for publication

The authors declare that they participated in this paper willingly, and the authors declare to consent to the publication of this paper.

Competing interests

The authors declare no competing interests.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

da Silva, A.E., Cuesta, J.L., Lopes, J.C. et al. Grinding behavior of VP50IM steel using green and black silicon carbide compared to aluminum oxide wheel under different feed rates. Int J Adv Manuf Technol 117, 2639–2653 (2021). https://doi.org/10.1007/s00170-021-07826-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-07826-5

Keywords

Search

Navigation