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Sustainable grinding: mitigating CO2 emissions through MQL+WCJ technique in AISI VP50 steel processing

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Abstract

In plastic mold injectors, VP50 steel stands out as one of the most used materials. Their application demands high mechanical strength to ensure the repeatability of plastic production. VP50 steel possesses exceptional wear resistance and easy machinability, making it an indispensable choice for mold steels. Therefore, it is common to grinding this material to obtain the specified tolerances. In machining processes, cutting fluid presents itself as a fundamental component, as they are responsible for the refrigeration and lubrication of the cutting interface. However, cutting fluids are emulsions of water and mineral oil composed of hydrocarbons derived from petroleum refining, which, when burned, can release CO2, contributing to the strengthening of the greenhouse effect. Considering the consequences of global warming and the future of humanity due to CO2 emissions, the United Nations (UN) established an agenda called Sustainable Development Goals (SDGs) to be achieved by the year 2030. Aligning the SDGs with the setbacks present in the lubrication-cooling technique in the grinding process, alternative options arise, as well as the minimum quantity of lubricant (MQL) and the wheel cleaning jet (WCJ) system. This research analyzes the grinding behavior of VP50 steel. For this, techniques are used comparatively, conventional flood, pure MQL, and MQL+WCJ. Analyses are performed under three feed rate regimes, 0.25, 0.50, and 0.75 mm/min, obtaining the following output parameters, surface roughness, roundness error, diametrical wheel wear, G-ratio, grinding power, acoustic emission, cost, and pollution. The results obtained in this paper show the great industrial applicability of MQL, with and without WCJ. Thus, the results showed that different machining techniques and materials could be used to minimize the use of cutting fluid.

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Acknowledgements

The authors are thankful to Schaeffler Technologies AG & Co by the support to this work.

Funding

The authors are thankful to São Paulo Research Foundation (FAPESP) (Grant 2023/00741-2), CAPES (Coordination for the Improvement of Higher Level Education Personnel), and National Council for Scientific and Technological Development (CNPq) (Grant PIBIC - 2022/2023).

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Authors and Affiliations

  1. Department of Mechanical Engineering, Sao Paulo State University – Unesp, Bauru, SP, 17033-360, Brazil

    Fernando Sabino Fonteque Ribeiro, Matheus de Souza Rodrigues, Rafael Lemes Rodriguez, Anthony Gaspar Talon, Luiz Eduardo De Angelo Sanchez, Eduardo Carlos Bianchi & José Claudio Lopes

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  1. Fernando Sabino Fonteque Ribeiro
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  2. Matheus de Souza Rodrigues
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  3. Rafael Lemes Rodriguez
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Contributions

F.S.F.R.: writing original draft; writing review and editing; visualization; conceptualization; formal analysis; investigation; validation.

M.S.R.: writing original draft; writing review and editing; visualization; conceptualization.

R.L.R.: writing original draft; writing review and editing; visualization; conceptualization; formal analysis; investigation; validation.

A.T.G.: writing original draft; resources; conceptualization; methodology; project administration.

L.E.A.S: writing-review and editing; conceptualization; supervision.

E.C.B.: conceptualization; methodology; formal analysis; investigation; validation.

J.C.L.: funding acquisition; conceptualization; resources; supervision; project administration.

Corresponding author

Correspondence to Anthony Gaspar Talon.

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Ribeiro, F.S.F., Rodrigues, M.d.S., Rodriguez, R.L. et al. Sustainable grinding: mitigating CO2 emissions through MQL+WCJ technique in AISI VP50 steel processing. Int J Adv Manuf Technol 129, 5421–5433 (2023). https://doi.org/10.1007/s00170-023-12673-7

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