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Eco-friendly thinking toward mitigating the greenhouse effect applied to the alumina grinding process

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Abstract

The grinding process manufactures parts with geometric and dimensional precision and surface finish. During the procedure, material removal requires high energy and generates heat in the cutting zone. The grinding of advanced ceramics, such as alumina (Al2O3, 97% purity), is even more complex and economically expensive due to its mechanical properties. Thus, cooling and lubrication techniques are needed to control temperatures. The conventional flood technique is currently the most used, but it has a high environmental impact combined with unhealthy chemical agents in the cutting fluid. As a result, cutting fluids are the inputs that pose the most significant risks and damage to the environment and human health. Applying atomized and pressurized cutting fluid directly to the cutting zone has shown manufacturing potential compared to the conventional flood technique to solve these problems. Despite this, the minimum quantity of lubricant (MQL) technique does not provide good thermal dissipation compared to traditional methods, requiring the inclusion of auxiliary systems. In addition, one of these techniques deals with adding different proportions of water to the mixture, aiming to improve the heat transfer of the process and minimize the phenomenon of clogging the surface of the grinding wheel. Thus, this study analyzed the performance of a diamond grinding wheel in the advanced process of ceramic grinding using different proportions of cutting fluid applied to the MQL system, as follows: MQL + Pure (Pure—100% cutting fluid), MQL + 50% (50% cutting fluid and 50% water), MQL + 25% (25% cutting fluid and 75% water), and MQL + 15% (15% cutting fluid and 85% water) compared to the flood technique. Thus, surface roughness, soil surface topography by confocal microscopy analysis, roundness error, diametral grinding wheel wear, G-ratio, grinding cost analyses, and CO2 pollution analyses were evaluated. In addition, MQL applications revealed fewer pollutants. Furthermore, they were more economical application conditions from the grinding cost analysis, making them a great eco-friendly alternative for use in the industrial sector.

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Acknowledgements

The authors thank the Coordination for the Improvement of Higher-Level Education Personnel (CAPES) and the National Council for Scientific and Technological Development (CNPq) for funding this research. The authors also thank companies Nikkon Ferramentas de Corte Ltda-Saint Gobain Group and Quimatic Tapmatic Ltda for the donations of the grinding wheel and the cutting fluids, respectively.

Funding

This work was supported by the Coordination for the Improvement of Higher-Level Education Personnel (CAPES), the National Council for Scientific and Technological Development (CNPq) (Grant PIBIC-2022/2023), and São Paulo Research Foundation (FAPESP) (Grant 2021/08549–8).

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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

    Bruno Biondo Domingues, Rafael Lemes Rodriguez, Guilherme Guerra de Souza, Benício Nacif Ávila, Matheus de Souza Rodrigues, Luiz Eduardo de Angelo Sanchez, Eduardo Carlos Bianchi & José Claudio Lopes

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

    Fernando Sabino Fonteque Ribeiro

  3. Department of Mechanical Engineering, University of São Paulo, São Carlos School of Engineering, São Carlos, São Paulo, Brazil

    Alessandro Roger Rodrigues

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Contributions

Bruno Biondo Domingues: writing the original draft; visualization; conceptualization; formal analysis; investigation; validation. Rafael Lemes Rodriguez: writing the original draft; resources; conceptualization; methodology; project administration. Guilherme Guerra de Souza: software; writing, review, and editing; investigation; validation. Benício Nacif Ávila: writing, review and editing; visualization; conceptualization; formal analysis; investigation; validation. Matheus de Souza Rodrigues: writing, review and editing; visualization; conceptualization; formal analysis; investigation; validation. Fernando Sabino Fonteque Ribeiro: writing, review and editing; investigation; validation. Alessandro Roger Rodrigues: conceptualization; methodology; formal analysis; investigation; validation. Luiz Eduardo De Angelo Sanchez: software; supervision; project administration. Eduardo Carlos Bianchi: writing, review and editing; conceptualization; supervision. José Claudio Lopes: funding acquisition; conceptualization; resources; supervision; review and editing; project administration.

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Correspondence to José Claudio Lopes.

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Domingues, B.B., Rodriguez, R.L., Souza, G.G. et al. Eco-friendly thinking toward mitigating the greenhouse effect applied to the alumina grinding process. Int J Adv Manuf Technol 124, 2171–2183 (2023). https://doi.org/10.1007/s00170-022-10598-1

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