Top

The International Journal of Advanced Manufacturing Technology

Published in:

02-02-2022 | ORIGINAL ARTICLE

Application of optimized lubri-cooling technique in through-feed centerless grinding process of bearing steel SAE 52100

Authors: Luiz Maurício Gonçalves Neto, Rafael Lemes Rodriguez, José Claudio Lopes, Fernando Sabino Fonteque Ribeiro, Grzegorz M. Królczyk, Luiz Eduardo de Ângelo Sanchez, Hamilton José de Mello, Eduardo Carlos Bianchi

Published in: The International Journal of Advanced Manufacturing Technology | Issue 1-2/2022

Activate our intelligent search to find suitable subject content or patents.

search-config

AI-assisted search

Off

Abstract

Through-feed centerless grinding is a high-productivity machining process widely used for mass production of cylindrical parts and rotationally symmetrical parts in automotive and bearing industries. Grinding process is strictly related to large amount of heat generated in the cutting zone, i.e., the interface between the workpiece and the abrasive tool. This process characteristic makes pivotal and indispensable the effects of lubrication and cooling provided by metal working fluid (MWF) in order to avoid thermal damage to the part during grinding. In this regard, this work aims to contribute to the study and application of cutting fluid in the process of this grinding process, comparing the effects in terms of workpiece integrity between the conventional technique and the optimized technique developed for the rational use of cutting fluids by the application of a novel multitubular nozzle. The multitubular nozzle was employed with emulsion (ME) and emulsion and compressed air simultaneously (ME + CA). Both techniques were compared to conventional nozzle (CN) application. All techniques were tested for four different flow rates: 10, 20, 30, and 40 L/min. Surface roughness of the ground surface, roundness deviation, and residual stress were analyzed. Additionally, optical microscopy images of grinding wheel cutting surface and SEM images for each condition surface were recorded. Regarding the three techniques of cutting fluid application (CN, ME, and ME + CA) in the process of through-feed centerless grinding, in general, a better performance was recorded for application of the new concept of developed multi-tube nozzle. The best grinding conditions were observed using ME + CA and ME for the flow rate of 40 L/min.

previous article Evaluation of the use of vegetable oils in the grinding of AISI 4340 steel

next article An artificial neural network approach for parametric study on welding defect classification

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

über 102.000 Bücher
über 537 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Finance + Banking
Management + Führung
Marketing + Vertrieb
Maschinenbau + Werkstoffe
Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

inform now

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

über 67.000 Bücher
über 390 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Maschinenbau + Werkstoffe

Jetzt Wissensvorsprung sichern!

inform now

Gallego I (2007) Intelligent centerless grinding: increasing precision and productivity. Center for Materials Processing and Tribology Seminar

Krajnik P, Drazumeric R, Vrabic R, Kopac J (2009) Advances in centerless grinding modelling and simulation. Advances in Production Engineering & Management 3:115–126 ISSN 1854–6250

Shih AJA (2001) New regulating wheel truing method for through-feed centerless grinding. J Manuf Sci Eng

Krajnik P, Drazumeric R, Vengust I et al (2008) Simulation of workpiece kinematics in centreless throughfeed grinding. In: Mitsuishi M, Ueda K, Kimura F, editors. Manufacturing systems and technologies for the new frontier: The 41st CIRP Conference on Manufacturing Systems May 26‐28, 2008, Tokyo, Japan. London: Springer London 2008:455–8

Meyer B, Krajnik P (2007) Simulation macht das Spitzenlosschleifen kleiner Stückzahlen rentabler. MM- MaschinenMarkt - Das Portal Industrie

Schmidt E (1989) Standzeituntersuchung an Schleifscheiben. Diplomarbeit, Fachhochschule des Landes Rheinlend Pfalz

Otaghvar MH, Hahn B, Werner H, Omiditabrizi H, Bähre D (2019) Optimization of centerless through-feed grinding using 3D kinematic simulation. Procedia CIRP 79:308–312CrossRef

Marinescu ID, Rowe WB, Dimitrov B, Ohmori H (2013) Tribology of abrasive machining processes. Elsevier. https://doi.org/10.1016/C2010-0-67070-2CrossRef

Malkin S, Guo C (2007) Thermal analysis of grinding. CIRP Ann Manuf Technol

10.

Bianchi EC, Rodriguez RL, Hildebrandt RA, Lopes JC, de Mello HJ, da Silva RB, de Aguiar PR (2018) Plunge cylindrical grinding with the minimum quantity lubrication coolant technique assisted with wheel cleaning system. Int J Adv Manuf Technol 95:2907–2916. https://doi.org/10.1007/s00170-017-1396-5CrossRef

11.

Malkin S, Guo C (2008) Grinding technology: theory and applications of machining with abrasives. Industrial Press, New York, p p372

12.

Brinksmeier E, Garbrecht M, Heinzel C, Koch T (2009) Eckebrecht, J. Current approaches in design and supply of metalworking fluids. Tribology & Lubrificationtechnology

13.

Irani RA, Bauer RJ, Warkentin A (2005) A review of cutting fluid application in the grinding process. International Journal of Machine Tools & Manufacture: Design, Research and Application 45:1696–1705CrossRef

14.

Tawakoli T, Hadad MJ, Sadeghi MH (2010) Investigation on minimum quantity lubricant-MQL grinding of 100Cr6 hardened steel using different abrasive and coolant–lubricant types. Int J Mach Tool Manuf

15.

Babic D, Murray B, Torrance AA (2005) Mist jet cooling of grinding processes. Int J Mach Tools Manuf 45:1171–1177CrossRef

16.

Klocke F (2009) Manufacturing processes 2 - grinding, honing, lapping (RWTH edition). translator a. Kuchle. Springer, Berlin

17.

Webster JA, Grün P (2008) Coolant calculus — directing coolant into the right place, at the right speed, in the right quantity. Cutting Tool Engineering Magazine 60(2)

18.

Tawakoli T, Rabiey M (2009) Trockenschleifen mit CBN-Schleifscheiben – Der Effekt der Makrotopographie. Wissenschaft & Forschung

19.

Sanchez JA, Pombo I, Alberdi R, Izquierdo B, Ortega N, Plaza S, Martinez-Toledano J (2010) Machining evaluation of a hybrid MQL-CO2 grinding technology. J Clean Prod 18:1840–1849. https://doi.org/10.1016/J.JCLEPRO.2010.07.002CrossRef

20.

Sreejith PS, Ngoi BKA (2001) Dry machining: machining of the future. J Mater Process Technol (101):1–3

21.

Sen B, Mia M, Krolczyk GM, Mandal UK, Mondal SP (2021) Eco-friendly cutting fluids in minimum quantity lubrication assisted machining: a review on the perception of sustainable manufacturing. Int J Precis Eng Manuf Green Tech. https://doi.org/10.1007/s40684-019-00158-6

22.

Tawakoli T, Rabiey M (2008) An innovative concept and its effects on wheel surface topography in dry grinding by resin and vitrified bond CBN wheel. Mach Sci Technol 12(4):514–528CrossRef

23.

Khanna N, Shah P, Maruda RW, Krolczyk GM, Hegab H (2020) Experimental investigation and sustainability assessment to evaluate environmentally clean machining of 15–5 PH stainless steel. J Manuf Process 56:1027–1038CrossRef

24.

Maruda RW, Krolczyk GM, Wojciechowski S, Powalka B, Klos S, Szczotkarz N, Matuszak M, Khanna N (2020) Evaluation of turning with different cooling-lubricating techniques in terms of surface integrity and tribologic properties. Tribol Int 106334:106334. https://doi.org/10.1016/j.triboint.2020.106334CrossRef

25.

De Oliveira DJ, Guermandi LG, Bianchi EC, Diniz AE, De Aguiar PR, Canarim RC (2012) Improving minimum quantity lubrication in CBN grinding using compressed air wheel cleaning. J Mater Process Technol 212:2559–2568. https://doi.org/10.1016/j.jmatprotec.2012.05.019CrossRef

26.

Klocke F, Schulz A, Gerschwiler K, Rehese M (1998) Clean manufacturing technologies — the competitive edge of tomorrow. Int J Manuf Sci Prod 1(2):77–86CrossRef

27.

Rodriguez RL, Lopes JC, Garcia MV, Ribeiro FSF, Diniz AE, de Angelo Sanchez LE, José de Mello H, Roberto de Aguiar P, Bianchi EC (2021) Application of hybrid eco-friendly MQL+WCJ technique in AISI 4340 steel grinding for cleaner and greener production. J Clean Prod 124670:124670. https://doi.org/10.1016/j.jclepro.2020.124670CrossRef

28.

Lopes JC, Ventura CEH, Rodriguez RL, Talon AG, Volpato RS, Sato BK, de Mello HJ, Aguiar PR, Bianchi EC (2018) Application of minimum quantity lubrication with addition of water in the grinding of alumina. Int J Adv Manuf Technol 97:1951–1959. https://doi.org/10.1007/s00170-018-2085-8CrossRef

29.

De Moraes DL, Garcia MV, Lopes JC, Ribeiro FSF, de Angelo Sanchez LE, Foschini CR, de Mello HJ, Aguiar PR, Bianchi EC (2019) Performance of SAE 52100 steel grinding using MQL technique with pure and diluted oil. Int J Adv Manuf Technol 105:4211–4223. https://doi.org/10.1007/s00170-019-04582-5CrossRef

30.

Garcia MV, Lopes JC, Diniz AE, Rodrigues AR, Volpato RS, de Sanchez LE, de Mello HJ, Aguiar PR, Bianchi EC (2020) Grinding performance of bearing steel using MQL under different dilutions and wheel cleaning for green manufacture. J Clean Prod 257

31.

Monici RD, Bianchi EC, Catai RE, Aguiar PR (2006) Analysis of the different forms of application and types of cutting fluid used in plunge cylindrical grinding using conventional and superabrasive CBN grinding wheels. Int J Mach Tool Manuf

32.

Macherauch E (1987) Introduction to residual stress. In: Niku-Lari, A. Advances in surface treatments: technology-applications-effects. International Guidebook on Residual Stresses. Oxford: Pergamon Press (4):1–36

33.

Field M, Kahles JF, Koster WP (1997) Surface finish and surface integrity. In: Several Authors. ASM International. ASM Handbook: Machining. USA: Metcut Research Associates (16):19–36

34.

Ramesh K, Huang H, Yin L (2004) Analytical and experimental investigation of coolant velocity in high speed grinding. Int J Mach, Tool Manuf 44(10):1069–1076CrossRef

35.

Yoshimura H, Itogawa F, Nakamura T, Niwa K (2005) Development of nozzle system for oil-on-water droplet metalworking fluid and its application to practical production line. JSME Int J 48(4):723–729. https://doi.org/10.1299/jsmec.48.723CrossRef

36.

Sato BK, Lopes JC, Diniz AE, Rodrigues AR, de Mello HJ, Sanchez LEA, Aguiar PR, Bianchi EC (2020) Toward sustainable grinding using minimum quantity lubrication technique with diluted oil and simultaneous wheel cleaning. Tribol Int 147:106276. https://doi.org/10.1016/j.triboint.2020.106276CrossRef

37.

Bianchi EC, Sato BK, Sales AR, Lopes JC, de Mello HJ, de Angelo Sanchez LE, Diniz AE, Aguiar PR (2018) Evaluating the effect of the compressed air wheel cleaning in grinding the AISI 4340 steel with CBN and MQL with water. Int J Adv Manuf Technol 95:2855–2864. https://doi.org/10.1007/s00170-017-1433-4CrossRef

38.

Daniel CM, Rao KV, Olson WW, Sutherland JW (1996) Effect of cutting fluid properties and application variables on heat transfer in turning and boring operations. Japan/USA Symp Flex Autom 2:1119–1126

39.

Malkin S (1989) Grinding technology: theory and application of machining with abrasives, 1st edn. Ellis Horwood Limited, Chichester

40.

Walker T (2013) The MQL handbook — a guide to machining with minimum quantity lubrication.[s.l.] UnistInc

41.

Rodriguez RL, Lopes JC, Hildebrandt RA, Perez RRV, Diniz AE, de Ângelo Sanchez LE, Rodrigues AR, de Mello HJ, de Aguiar PR, Bianchi EC (2019) Evaluation of grinding process using simultaneously MQL technique and cleaning jet on grinding wheel surface. J Mater Process Technol 271:357–367. https://doi.org/10.1016/j.jmatprotec.2019.03.019CrossRef

42.

De Martini FL, Lopes JC, Volpato RS, Diniz AE, de Oliveira RFM, de Aguiar PR et al (2018) Comparative analysis of two CBN grinding wheels performance in nodular cast iron plunge grinding. Int J Adv Manuf Technol 98:237–249. https://doi.org/10.1007/s00170-018-2133-4CrossRef

43.

Rodriguez RL, Lopes JC, Garcia MV, Tarrento GE, Rodrigues AR, de Mello HJ, de Aguiar PR, Bianchi EC (2020) Grinding process applied to workpieces with different geometries interrupted using CBN wheel. Int J Adv Manuf Technol 107:1265–1275. https://doi.org/10.1007/s00170-020-05122-2CrossRef

44.

Malkin S, Guo C (2008) Grinding technology. In: Theory and applications of machining with abrasives. 2.ed

45.

Demeter EC, Hockenberger MJ (1997) The application of tool path compensation for the reduction of clamping-induced geometric error. Int J Prod Res 35(12)

Title: Application of optimized lubri-cooling technique in through-feed centerless grinding process of bearing steel SAE 52100
Authors: Luiz Maurício Gonçalves Neto
Rafael Lemes Rodriguez
José Claudio Lopes
Fernando Sabino Fonteque Ribeiro
Grzegorz M. Królczyk
Luiz Eduardo de Ângelo Sanchez
Hamilton José de Mello
Eduardo Carlos Bianchi
Publication date: 02-02-2022
Publisher: Springer London
Published in: The International Journal of Advanced Manufacturing Technology / Issue 1-2/2022
Print ISSN: 0268-3768
Electronic ISSN: 1433-3015
DOI: https://doi.org/10.1007/s00170-022-08686-3

Springer Professional

Abstract

Please log in to get access to your license.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Springer Professional "Technik"

Other articles of this Issue 1-2/2022

Readiness levels of Industry 4.0 technologies applied to aircraft manufacturing—a review, challenges and trends

Modeling and analysis of tool-chip contact model during quasi-intermittent vibration assisted swing cutting based on two-zone theory

Bill of material consistency reconstruction method for complex products driven by digital twin

Influences of the workpiece pose errors on gear skiving accuracy

Upset Protrusion Joining (UPJ) characteristics of cast AM60 magnesium alloy to join with dissimilar material

Soft computing-based process optimization in laser metal deposition of Ti-6Al-4 V

Premium Partners