The effect of wear phenomena of grinding wheels with sol-gel alumina on chip formation during internal cylindrical plunge grinding of 100Cr6 steel

Nadolny, Krzysztof; Kapłonek, Wojciech

doi:10.1007/s00170-016-8500-0

Cited by 22 publications

(6 citation statements)

References 27 publications

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“…Overview of research on grinding types, the different materials used, and methods used [22,23,24,25,26,27,28,29,30,31,32,33,34,35,36,37,38,39,40,41,42,43,44,45,46,47,48,49,50,51,52]. …”

Section: Figurementioning

confidence: 99%

Multi-Objective Optimization for Grinding of AISI D2 Steel with Al2O3 Wheel under MQL

et al. 2018

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In the present study, the machinability indices of surface grinding of AISI D2 steel under dry, flood cooling, and minimum quantity lubrication (MQL) conditions are compared. The comparison was confined within three responses, namely, the surface quality, surface temperature, and normal force. For deeper insight, the surface topography of MQL-assisted ground surface was analyzed too. Furthermore, the statistical analysis of variance (ANOVA) was employed to extract the major influencing factors on the above-mentioned responses. Apart from this, the multi-objective optimization by Grey–Taguchi method was performed to suggest the best parameter settings for system-wide optimal performance. The central composite experimental design plan was adopted to orient the inputs wherein the inclusion of MQL flow rate as an input adds addition novelty to this study. The mathematical models were formulated using Response Surface Methodology (RSM). It was found that the developed models are statistically significant, with optimum conditions of depth of cut of 15 µm, table speed of 3 m/min, cutting speed 25 m/min, and MQL flow rate 250 mL/h. It was also found that MQL outperformed the dry as well as wet condition in surface grinding due to its effective penetration ability and improved heat dissipation property.

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“…Overview of research on grinding types, the different materials used, and methods used [22,23,24,25,26,27,28,29,30,31,32,33,34,35,36,37,38,39,40,41,42,43,44,45,46,47,48,49,50,51,52]. …”

Section: Figurementioning

confidence: 99%

Multi-Objective Optimization for Grinding of AISI D2 Steel with Al2O3 Wheel under MQL

et al. 2018

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“…The combined effects of the processes strongly influence the course and results of abrasive machining. These processes can be divided into five basic groups: contact processes [1], friction processes [2,3], abrasive tool wear processes [2][3][4][5][6], workpiece wear processes [3], and lubrication processes [3,7]. Among the abovementioned processes, lubrication processes of the tool-workpiece contact zone have a key influence on the conditions of abrasive machining, as they affect the physicochemical processes of the contact.…”

Section: Introductionmentioning

confidence: 99%

Experimental Studies on the Centrifugal MQL-CCA Method of Applying Coolant during the Internal Cylindrical Grinding Process

Nadolny

Kieraś

2020

Materials

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This paper presents the results of experimental research concerning the possibility of supporting the cooling function during internal cylindrical grinding using the minimum quantity lubrication (MQL) method by additional delivery of a compressed cooled air (CCL) stream. The article presents a description of a hybrid method of cooling and lubrication of the grinding zone integrating centrifugal (through a grinding wheel) lubrication with the minimum quantity of lubricant and cooling with a compressed cooled air stream generated by a cold air gun (CAG). The methodology and results of experimental studies are also presented in detail, with the aim of determining the influence of the application of the hybrid method of cooling and lubrication of the machining zone on the course and results of the internal cylindrical grinding process of 100Cr6 steel in comparison with other methods of cooling and lubrication, as well as compared with dry grinding. The research results obtained using the described hybrid method of cooling and lubrication of the grinding zone are related to the results obtained under the conditions of centrifugal MQL method, cooling with a stream of CCA, cooling and lubrication with a stream of oil-in-water emulsion delivered using the flood method, and dry grinding. The efficiency of the grinding process is evaluated (based on the average grinding power Pav, grinding wheel volumetric wear Vs, material removal Vw, and grinding ratio G), along with the thermal conditions of the process (based on the analysis of thermograms recorded by infrared thermal imaging method), the textures of machined surfaces (based on microtopography measured by contact profilometry), the state of residual stress in the surface layers of workpieces (determined by X-ray diffraction method), and the state of the grinding wheels’ active surfaces after grinding (based on microtopography measured by laser triangulation and images recorded with a digital measuring microscope). The obtained results of the analyses show that the application of the hybrid method allows for the longest wheel life among the five compared grinding methods, which is about 2.7 times the life of grinding wheels working under the flood cooling and centrifugal MQL methods, and as much as 8 times the life of grinding wheels working under the conditions of CCA only and dry grinding.

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“…Reduced tensile residual stresses even could enhance the product functionality leading to longer product life and less environmental impact [13]. The peripheral speeds used in grinding of hardened steel with seeded-gel wheels reported in previous works do not exceed 60 m/s [2,[8][9][10]. In most of them, the peripheral speeds are considerably lower than this value.…”

Section: Introductionmentioning

confidence: 99%

“…Starkov et al [8] found that CBN grinding wheel far outperforms in efficiency its analogs with microcrystalline corundum and white electrocorundum in profiling shaped broaches from hardened high speed at a peripheral speed of 30 m/min. Nadolny and Kaplonek [9] evaluated the effect of wear phenomena of grinding wheels with sol-gel alumina on chip formation during internal cylindrical plunge grinding of 100Cr6 steel at a peripheral speed of 60 m/min. They reported that a few spherical melted chips of various sizes were observed on the whole surface of the grinding wheel, indicating that during the grinding process a large amount of grinding heat is generated and conducted into the chips.…”

Section: Introductionmentioning

confidence: 99%

Performance comparison of seeded-gel and CBN grinding wheels for cylindrical plunge grinding of 100Cr6 steel

Arantes

Polli

2020

J Braz. Soc. Mech. Sci. Eng.

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The selection of the grinding wheel is an important step during the process planning of grinding operations, especially for high-quality small components of hardened steel. The correct choice of the grinding wheel and the proper selection of cutting parameters can provide ground surfaces with high quality and positively affect the economic aspects of the process. The present work compares the performance of seeded-gel and CBN grinding wheels in external cylindrical plunge grinding of 100Cr6 steel in a range of high peripheral speeds, where it is possible to use both grinding wheels. The comparison was made taking into account the workpiece surface roughness and indices like the grinding ratio, specific grinding energy and grinding efficiency. The use of the CBN grinding wheel resulted in lower surface roughness values than those obtained with the seeded-gel grinding wheel. For both grinding wheels, there was a tendency that increasing peripheral speed reduces the surface roughness values. The best performance of the seeded-gel grinding wheel was found at 150 mm 3 /min/mm, where the grinding efficiency increased with the peripheral speed, and the highest value of all the performed experiments was achieved at 80 m/s. This value was approximately three times the grinding efficiency of the CBN grinding wheel under the same cutting conditions. The highest grinding efficiency for the CBN grinding wheel was achieved at 200 mm 3 /min/mm and 80 m/s. The grinding efficiency of the seeded-gel wheel dropped for this cutting condition due to higher wheel wear.

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The effect of wear phenomena of grinding wheels with sol-gel alumina on chip formation during internal cylindrical plunge grinding of 100Cr6 steel

Cited by 22 publications

References 27 publications

Multi-Objective Optimization for Grinding of AISI D2 Steel with Al2O3 Wheel under MQL

Multi-Objective Optimization for Grinding of AISI D2 Steel with Al2O3 Wheel under MQL

Experimental Studies on the Centrifugal MQL-CCA Method of Applying Coolant during the Internal Cylindrical Grinding Process

Performance comparison of seeded-gel and CBN grinding wheels for cylindrical plunge grinding of 100Cr6 steel

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