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Advanced ceramic grinding process combined to hazard mitigation to the employees’ health by using an alternative lubri-refrigeration technique

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Abstract

The sustainable industry is becoming a global trend that aims to align productivity, quality, and environmental preservation. In the grinding process, the need arises to develop new technologies to replace cutting fluids, which are highly toxic substances. The minimum quantity of lubrication (MQL) technique is alternative lubrication and cooling method that makes machining more ecological. However, its application is still tiny due to its low cooling power and cleaning of the workpiece-tool interface. On the other hand, the grinding conditions improve when associated with the wheel cleaning jet (WCJ) system, which consists of applying an inclined compressed air jet on the grinding wheel, avoiding clogging and the adhesion of chips on the surface of the grinding wheel. From this perspective, this work aims to perform a comparative analysis between the flood method and the MQL and MQL + WCJ techniques, in the external cylindrical grinding of alumina ceramic (Al2O3), at feed rates of 0.25, 0.50, and 0.75 mm/min. The output parameters analyzed will be diametrical wheel wear, G-ratio, surface roughness, roundness error, grinding power, cost, and pollution analysis. The G-ratio was 40% better using MQL + WCJ compared to MQL, while the grinding cost per piece with MQL + WCJ represented about 24% of the price of the conventional method. The results show that the association of WCJ to MQL improves the efficiency of the MQL technique, guaranteeing good results and being an eco-friendly technique.

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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, Dinser Ferramentas Diamantadas for donating the diamond grinding wheel, and Quimatic Tapmatic Ltda, and ITW Chemical Products Ltda for donating the cutting fluids.

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 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

    Lucas de Martini Fernandes, Rafael Liberatti Javaroni, Matheus de Souza Rodrigues, Benício Nacif Ávila, Douglas Lyra de Moraes, Thiago Valle França, 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, Parana, Brazil

    Fernando Sabino Fonteque Ribeiro

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

    Alessandro Roger Rodrigues

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  1. Lucas de Martini Fernandes
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Contributions

Lucas de Martini Fernandes: writing the original draft; visualization; conceptualization; formal analysis; investigation; validation. Rafael Liberatti Javaroni: writing, review and editing; investigation; validation. Matheus de Souza Rodrigues: Software; writing, review and editing; investigation; validation. Benício Nacif Ávila: writing, review and editing; visualization; conceptualization; formal analysis; investigation; validation. Douglas Lyra de Moraes: writing the original draft; resources; conceptualization; methodology; project administration. Fernando Sabino Fonteque Ribeiro: writing, review and editing; visualization; conceptualization; Alessandro Roger Rodrigues: Conceptualization; methodology; formal analysis; investigation; validation. Thiago Valle França: formal analysis; investigation; validation. Luiz Eduardo de Angelo Sanchez: writing, review and editing; conceptualization; supervision. Eduardo Carlos Bianchi: funding acquisition; conceptualization; resources; supervision; project administration. José Claudio Lopes: supervision; project administration. All authors read and approved the final manuscript.

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Correspondence to José Claudio Lopes.

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Fernandes, L.d.M., Javaroni, R.L., Rodrigues, M.d. et al. Advanced ceramic grinding process combined to hazard mitigation to the employees’ health by using an alternative lubri-refrigeration technique. Int J Adv Manuf Technol 127, 2921–2934 (2023). https://doi.org/10.1007/s00170-023-11674-w

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