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Application of MQL with cooled air and wheel cleaning jet for greener grinding process

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Abstract

Metalworking fluids (MWF) or flooded process based on mineral oil are widely used in industry, which is unsustainable and causes damage to employees and the environment, in addition to making up a significant part of the machining cost. On the other hand, abrasive machining methods, such as grinding, are increasingly used for their excellent finish and geometric precision but use large quantities of metalworking fluids. This work evaluates the alternative methods Minimum Lubricant Quantity (MQL), MQL + Cooled Air (CA), MQL + Wheel Cleaning Jet (WCJ), and MQL + Cooled WCJ in the grinding of AISI 4340 steel compared to the application of flooded process. Surface roughness, roundness error, G ratio, grinding power, specific energy, microhardness, cost per piece, and carbon emission tests were applied. From the results, MQL reduced the cost of grinding around 90% and carbon emission by 67% compared to grinding with flooded process. The MQL + CWCJ produced the best results of surface quality compared to other alternative techniques, significantly approaching the results of the flooded process.

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Acknowledgements

The authors also thank companies Nikkon Ferramentas de Corte Ltda and Norton Abrasives—Saint Gobain Group for providing the grinding wheel, 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

Special thanks to FAPESP (São Paulo Research Foundation – Proc. 2018/22661–2) for financial support. 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.

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

    Douglas Maiochi Daniel, Douglas Lyra de Moraes, Mateus Vinicius Garcia, José Claudio Lopes, Rafael Lemes Rodriguez, Fernando Sabino Fonteque Ribeiro, Luiz Eduardo de Angelo Sanchez & Eduardo Carlos Bianchi

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  1. Douglas Maiochi Daniel
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Contributions

Douglas Maiochi Daniel: writing—original draft; writing—review and editing; visualization; conceptualization; formal analysis; investigation; validation. Douglas Lyra de Moraes: writing—original draft; writing—review and editing; data curation; formal analysis. Mateus Vinicius Garcia: writing—original draft; investigation; data curation; formal analysis. José Claudio Lopes: writing—original draft; resources; conceptualization; methodology; project administration. Rafael Lemes Rodriguez: writing—original draft; investigation; validation. Fernando Sabino Fonteque Ribeiro: conceptualization; methodology; validation; writing—original draft. Luiz Eduardo de Angelo Sanchez: writing—review and editing; conceptualization; supervision. Eduardo Carlos Bianchi: funding acquisition; conceptualization; resources; supervision; project administration.

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Correspondence to Eduardo Carlos Bianchi.

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Daniel, D.M., Moraes, D.L.d., Garcia, M.V. et al. Application of MQL with cooled air and wheel cleaning jet for greener grinding process. Int J Adv Manuf Technol 125, 435–452 (2023). https://doi.org/10.1007/s00170-022-10712-3

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