Influence of nanofluid application on wheel wear, coefficient of friction and redeposition phenomenon in surface grinding of Ti-6Al-4V

Abstract

Difficulties in the grinding of Ti-6Al-4V originate from the three basic properties: poor thermal conductivity, high chemical reactivity and low volume specific heat of the material. Under severe grinding conditions, all these factors together lead to the accelerated wheel loading and redeposition of chips over the work surface. Redeposition and wheel loading have a significant effect on the surface finish, grinding forces, power consumption and wheel life. In this study, waterbased Al 2 O 3 nanofluid as metalworking fluid is applied during the surface grinding of Ti-6Al-4V under minimum quantity lubrication mode after dressing the wheel with different dressing overlap ratios. The severity of the redeposition over the work surface was observed by measuring various surface profiles taken perpendicular to the grinding direction at several locations on the ground surface. The nanofluid application was able to prevent redeposition over work surface that became evident from the measured surface finish parameters that results along the grinding direction. Coefficient of friction was estimated On-Machine using the measured forces for different wheel work speed ratios, depth of cut and dressing overlap ratios. The results showed the effectiveness of nanofluid in reducing friction at high material removal rate (i.e. high depth of cut and high speed ratio) conditions when compared to the dry environment. From the measured forces variation with respect to the number of passes, it became evident that, nanofluid application delayed the frequency of wheel loading and grit fracturing cycle, which leads to the increase in the wheel life.

Experimental investigation of graphene nanoplatelets–based minimum quantity lubrication in grinding Inconel 718

“…Thus, the addition of nanosized solid particles to grinding fluids can enhance the heat exchange capability of grinding fluids which in turn help in better cooling of the grinding zone by dissipating the heat generated. This is evident from the works carried out by various researchers, [3][4][5][6][7][8][9][10] in which MQL grinding performance was improved by adding various nanoparticles such as copper, nickel, Al 2 O 3 and carbon nanotubes. In all these studies, addition of nanoparticles resulted in the reduction of specific grinding energy and improvement in wheel life and quality of the workpiece surface.…”

Suitability of aqueous MoS2 nanofluid for small quantity cooling lubrication–assisted diamond grinding of WC-Co cermets

“…The same was observed as well during the grinding of Ti-6Al-4V alloys with water-dispersed multiwall carbon nanotube (MWCNT) and Al 2 O 3 nanofluids used as cutting fluids in SQCL mode. 19 The versatility of nanofluid-assisted MQL as a cooling lubrication stratagem could be understood further from the findings of Setti et al, 20 where the use of aqueous Al 2 O 3 nanofluid arrested wheel loading and re-deposition on the surface of the specimen. Water-dispersed MoS 2 nanofluids also displayed the same tendency to stick to the periphery of the wheel as was observed during grinding of AISI 52100.…”

Nanofluids revisited

“…However, no significantly lower temperatures could be found using nanofluids instead of pure water for cooling. Setti et al [100] also suggested the use of Al 2 O 3 ÁH 2 O nanofluids in the sophisticated grinding process of Ti6Al-4V showing that wheel life can be increased. Paul et al [101] suggested using magnetorheological fluids to reduce tool vibration in material processing.…”