A surface and sub-surface quality evaluation of three cast iron grades after grinding under various cutting conditions

Silva, Rosemar Batista da; Lima, Mariana Landim Silveira; Pereira, Mayara Fernanda; Abrão, Bruno Souza; Silva, Leonardo Rosa Ribeiro da; Bianchi, Eduardo Carlos; Machado, Álisson Rocha

doi:10.1007/s00170-018-2628-z

Cited by 23 publications

(7 citation statements)

References 11 publications

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“…Furthermore, Zeng et al [ 66 ] found that mechanically polished CoCrMo alloys exhibited hardened surface layers (containing martensitic phases and deformation twins), although they tended to be only ≈1 μm or so in thickness. Much deeper deformed layers have been found in other cases, with a sensitivity to alloy type being found for various cast irons [ 67 ] and steels. [ 68,69 ]…”

Section: Microstructural (“Sample‐specific”) Effectsmentioning

confidence: 98%

Profilometry‐Based Inverse Finite Element Method Indentation Plastometry

Clyne

Campbell²,

Burley³

et al. 2021

Adv Eng Mater

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This is a review of the current state‐of‐the‐art regarding a particular approach to extraction of the (quasistatic) stress–strain relationship of a metallic sample from an indentation experiment. It is based on the application of a relatively high load (kN range) to the sample via a large spherical indenter (≈1 mm radius), followed by measurement of the indent profile. This profile is then used as the target outcome for inverse finite element method (FEM) modeling of the test, aimed at converging on the best fit set of parameter values in a constitutive plasticity law (true stress–true strain relationship). This can then be used to simulate any specified loading configuration, including a conventional tensile test. Commercial products are now available in which the indentation, profilometry, and convergence operations are all automated and completed within a few minutes. The review covers the various conceptual and practical issues involved in implementation and optimization of these procedures, including both those related to the measurement system (experimental and FEM simulation) and those associated with the sample (such as anisotropy, inhomogeneities, and residual stresses). An attempt is made to convey an impression of the expected levels of reliability and also the scope for obtaining insights that are not readily obtainable using other types of test.

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Section: Microstructural (“Sample‐specific”) Effectsmentioning

confidence: 98%

Profilometry‐Based Inverse Finite Element Method Indentation Plastometry

Clyne

Campbell²,

Burley³

et al. 2021

Adv Eng Mater

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“…Before the microhardness measurements, ground workpieces were sanded employing silicon carbide sandpapers with 220, 320, 600, 800, 1000, and 1200 mesh and then polished using alumina paste of 0.1 µm size (metallography technique). Although the choice of carrying out the polishing process before measuring microhardness was due to in other works on grinding, the polishing process was also used successfully before the measurement of microhardness, as in a study developed by Silva et al [28], Moraes et al [29], Srivastava et al [30], Javaroni et al [31], and Garcia et al [32]. The microhardness was evaluated using a SHIMADZU HMV-2 series hardness tester with a Vickers penetrator (Barueri, Brazil).…”

Section: Methodsmentioning

confidence: 99%

Improvements of the MQL Cooling-Lubrication Condition by the Addition of Multilayer Graphene Platelets in Peripheral Grinding of SAE 52100 Steel

et al. 2021

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In most grinding processes, the use of cutting fluid is required, and research has been carried out to reduce the amount of fluid used due to costs and environmental impacts. However, such a reduction of fluid can result in thermal damage to the machined component because the amount of cutting fluid may not be sufficient to lubricate and cool the system. One way of improving the cutting fluid properties is to add micro or nanoparticles of solid lubricants. This paper aims to evaluate the performance of multilayer graphene platelets dispersed in cutting fluid and applied through the technique of minimum quantity of lubrication (MQL) during the peripheral surface grinding of SAE 52100 hardened steel. In this sense, the influence of these solid particles with respect to the surface and sub-surface integrity of the machined components was analyzed, performing the roughness and microhardness measurement and analyzing the ground surfaces. The results showed that the cooling–lubrication conditions employing graphene could obtain smaller roughness values and decreases of microhardness in relation to the reference value and components with better surface texture compared to the conventional MQL technique without solid particles.

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“…It is known from machining theory that as temperature decreases during machining, workpiece hardness and strength increase rapidly, what results in higher grinding force, thereby impairing the grindability of the cast iron when using conventional abrasive grinding wheel. In a recent work carried out by Da Silva et al [28], the authors evaluated the surface and subsurface quality of three cast iron grades, that includes cast iron one, during grinding under various cutting conditions. They tested only the conventional coolant delivery technique.…”

Section: Methodsmentioning

confidence: 99%

“…Also, this flow rate was adopted as standard in most of works in grinding developed in the same laboratory in which the current work was carried out. One of these works is that carried out by Da Silva et al [28] in grinding of several cast iron grades.…”

Section: Methodsmentioning

confidence: 99%

Assessment of the grindability of Inconel 718 under different coolant delivery techniques

Oliveira

Paiva

Silva

et al. 2019

J Braz. Soc. Mech. Sci. Eng.

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Nickel-based Inconel 718 stands out from other materials due to its peculiar combination of properties such as high mechanical strength, high hardness, high chemical inertia and low thermal expansion, as well as its ability to operate at high temperatures and in cryogenic conditions. These properties make this material suitable for aeronautic applications, especially for hot structural components, such as blades and discs of aircraft engines in which a high dimensional accuracy and low surface roughness are required. Such manufacturing requirements in general can be achieved through the grinding process. However, due to low thermal conductivity of both the Inconel 718 alloy and the conventional abrasive grinding wheels, most of heat generated during machining concentrates on the workpiece-grinding wheel interface. The usual practice for the removal of heat from grinding zone is by the application of high volume of coolants, but such technique can cause injury to the operator and harm to the environment, if special care with its use and disposal is not taken, which, in turn, increases the cost of the process. Furthermore, due to the poor machinability of Inconel 718, cutting conditions need to be different from those generally employed when grinding steels and cast irons, especially the depth of cut. Within this context, this study presents an approach for determining the grindability of Inconel 718 under different coolant delivery techniques (conventional and minimum quantity lubrication-MQL) and cutting conditions. Grinding tests were also carried out on a grey cast iron material for comparison purposes. Surface roughness, microhardness and surface texture of machined surfaces were the output parameters used to access the grindability of Inconel 718. Results showed that higher values of surface roughness were recorded after grinding the Inconel 718, compared to grey cast iron, thereby indicating the lower grindability of Inconel 718. No evidence of reduction in hardness due to thermal damage was observed after grinding both materials under the established cutting conditions.

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A surface and sub-surface quality evaluation of three cast iron grades after grinding under various cutting conditions

Cited by 23 publications

References 11 publications

Profilometry‐Based Inverse Finite Element Method Indentation Plastometry

Profilometry‐Based Inverse Finite Element Method Indentation Plastometry

Improvements of the MQL Cooling-Lubrication Condition by the Addition of Multilayer Graphene Platelets in Peripheral Grinding of SAE 52100 Steel

Assessment of the grindability of Inconel 718 under different coolant delivery techniques

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