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Eco-friendly machining of advanced ceramics: wheel cleaning jet for greenhouse gas reduction

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Abstract

The constant development of new materials, such as ceramics with high wear resistance, makes it necessary to adapt machining processes by creating new methods or improving existing ones. Moreover, grinding is widely used as a finishing process in workpieces since it provides excellent surface roughness and dimensional tolerances. Due to the high volume of cutting fluid used in conventional lubrication (flood), associated with harmful effects such as contamination and intoxication, alternative methods have become highly necessary. The minimum quantity lubrication (MQL) technique reduces fluid use but has low cooling capacity, in addition to barely removing chips, making it essential to seek improvements to make it competitive. In this sense, adding water to the MQL can improve the cooling capacity at the cost of reducing lubrication. At the same time, applying a wheel cleaning jet (WCJ) of compressed air assists in chip removal. Thus, this work aims to analyze the results of external cylindrical grinding of alumina (Al2O3) using a synthetic diamond grinding wheel, comparing the techniques of conventional MQL, diluted MQL, and MQL + WCJ against the flood method. Surface roughness, roundness deviation, diametrical wheel wear, G ratio, grinding power, tangential cutting force, grinding cost analyses, and CO2 pollution emission were conducted for this. The results show that adding water to MQL, associated with WCJ, significantly improved roughness, wear, and grinding power. Furthermore, the analysis of costs and pollution showed that using MQL significantly reduced costs and CO2 emissions, proving the socio-environmental advantage of the MQL method against the flood method.

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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), National Council for Scientific and Technological Development (CNPq) (grant PIBIC—2022/2023) and São Paulo Research Foundation (FAPESP) (grant 2023/00741–2).

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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

    Douglas Lyra de Moraes, Andrigo Elisiario da Silva, Lucas Marcel Aparecido Costa Pilati, Anthony Gaspar Talon, 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

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  1. Douglas Lyra de Moraes
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Contributions

Douglas Lyra de Moraes: writing the original draft, visualization, conceptualization, formal analysis, investigation, and validation. Andrigo Elisiario da Silva: writing the original draft, resources, conceptualization, and methodology. Lucas Marcel Aparecido Costa Pilati: software; writing, review, and editing; investigation; and validation. Anthony Gaspar Talon: writing, review, and editing; visualization; conceptualization; and project administration. Fernando Sabino Fonteque Ribeiro: writing, review, and editing; investigation; and validation. Luiz Eduardo De Angelo Sanchez: software, supervision, and project administration. Eduardo Carlos Bianchi: writing, review, and editing; conceptualization; and supervision. José Claudio Lopes: funding acquisition, conceptualization, resources, supervision, review and editing, and project administration.

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Correspondence to Anthony Gaspar Talon.

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de Moraes, D.L., da Silva, A.E., Pilati, L.M.A.C. et al. Eco-friendly machining of advanced ceramics: wheel cleaning jet for greenhouse gas reduction. Int J Adv Manuf Technol 132, 745–757 (2024). https://doi.org/10.1007/s00170-024-13433-x

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