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Wear Behaviour and Sustainability of Coated Abrasives in Grinding of Aluminium Alloy Using Minimum Quantity Lubrication

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Abstract

The consumption of coated abrasive papers has been greatly increased in grinding of aluminium gadget housings to achieve a mirror-like finish prior to cosmetic treatments; however, the rapid abrasive wear produces low sustainability and likewise massive wastage. Prevention of adhesion wear and control of the grinding temperature of the coated abrasive papers are key challenges for prolonging abrasives’ life, but can be managed by the MQL grinding system. This work investigates the influences of coated abrasives and environmental conditions on grinding force, material removal and machined surface topography; with the corresponding abrasive wear patterns under dry conditions and the developed MQL system in the grinding of aluminium alloy (6061-T6). The developed relationship between the stress flow and thermal softening on the workpiece showed a good correlation of ~ 96.3% for controlling grinding forces and the associated thermal effects. Material removal decreased when the adhesion in the pores developed into clusters, rather than abrasion wear. The ground surface roughness decreased when the wear of the abrasives altered the cutting action into a sliding friction. With MQL, the reduction of abrasive wear showed in a retarded process of adhesion and clogging, followed by a rapid increase of abrasion and attrition wear.

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Abbreviations

AH :

Projected indentation area in the normal direction

AP :

Projected indentation area in the tangential direction

b:

Estimated radius of the contact area

dg :

Value of the grain diameter

ft,i :

Tangential force on the ith abrasive grain

fn,i :

Normal force on the ith abrasive grain

Gr,k :

Grind force ratio

H:

Hardness of the workpiece

K1, K2, K3 :

Constants

Ks :

Flow stress of the workpiece

MQLP :

Blasting pressure of the MQL

t:

Indentation depth

V:

Grinding surface speed

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Acknowledgements

The authors would like to thank the Taiwan Ministry of Science and Technology for providing funds (106-2221-E-011-073) for completion of this work.

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Authors and Affiliations

  1. Department of Mechanical Engineering, National Taiwan University of Science and Technology, #43, Sec.4, Keelung Road, Taipei, 106, Taiwan, ROC

    Chunliang Kuo, Jingguo Yang & Juihung Wen

  2. High Speed 3D Printing Research Center, National Taiwan University of Science and Technology, #43, Sec.4, Keelung Road, Taipei, 106, Taiwan, ROC

    Chunliang Kuo

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  1. Chunliang Kuo
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Correspondence to Chunliang Kuo.

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Kuo, C., Yang, J. & Wen, J. Wear Behaviour and Sustainability of Coated Abrasives in Grinding of Aluminium Alloy Using Minimum Quantity Lubrication. Int. J. of Precis. Eng. and Manuf.-Green Tech. 7, 23–34 (2020). https://doi.org/10.1007/s40684-019-00108-2

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  • DOI: https://doi.org/10.1007/s40684-019-00108-2

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