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Grinding hardened steel using MQL associated with cleaning system and cBN wheel

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Abstract

The minimum quantity lubrication (MQL) is one of the most promising alternative techniques to replace the conventional application of cutting fluids. However, its use in grinding is still a challenge, as overheating and wheel clogging occur, leading to workpiece quality worsening. This work investigates a wheel cleaning jet associated with the MQL (MQL+WCJ) at three flow rates in grinding of AISI 4340 hardened steel with a cBN wheel, comparing the results with MQL and conventional methods. The output parameters assessed were workpiece surface roughness, roundness deviation, and microhardness, diametrical wheel wear, acoustic emission, and grinding power, and the machined surfaces were analyzed through microscopy techniques (optical, scanning electron, and confocal). The MQL+WCJ outperformed MQL in all the tested conditions. The application of the wheel cleaning jet reduced by up to 73% the wheel wear, 69% the surface roughness, 45% the roundness deviation, 60% the acoustic emission, and 24% the grinding power, regarding MQL without wheel cleaning, contributing to a more environmentally friendly and efficient grinding.

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Acknowledgments

The authors thank companies Nikkon Ferramentas de Corte Ltda - Saint Gobain Group for providing the grinding wheel and ITW Chemical Products for the donation of the cutting fluids, and the authors thank everyone by support to the research and opportunity for scientific and technological development.

Funding

This research received financial support from São Paulo Research Foundation (FAPESP—processes 2018/22661-2), CAPES (Coordination for the Improvement of Higher Level Education Personnel), and CNPq (National Council for Scientific and Technological Development).

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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, 17033-360, Brazil

    Rafael Liberatti Javaroni, José Claudio Lopes, Mateus Vinicius Garcia, Luiz Eduardo de Angelo Sanchez, Hamilton José de Mello & Eduardo Carlos Bianchi

  2. Department of Control and Industrial Processes, Federal Institute of Education Science and Technology of Parana, 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

    Paulo Roberto Aguiar

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  1. Rafael Liberatti Javaroni
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  2. José Claudio Lopes
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  3. Mateus Vinicius Garcia
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Correspondence to Eduardo Carlos Bianchi.

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Javaroni, R.L., Lopes, J.C., Garcia, M.V. et al. Grinding hardened steel using MQL associated with cleaning system and cBN wheel. Int J Adv Manuf Technol 107, 2065–2080 (2020). https://doi.org/10.1007/s00170-020-05169-1

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