Extending the possibilities of cryogenic assisted grinding

• Grant number: 18/16416-5
• Support Opportunities: Regular Research Grants
• Start date: January 01, 2021
• End date: March 31, 2024
• Field of knowledge: Engineering - Mechanical Engineering - Manufacturing Processes
• Agreement: DFG
• Principal Investigator: Eraldo Jannone da Silva
• Grantee: Eraldo Jannone da Silva
• Principal researcher abroad: Jan Christian Aurich
• Institution abroad: University of Kaiserslautern, Germany
• Host Institution: Escola de Engenharia de São Carlos (EESC). Universidade de São Paulo (USP). São Carlos , SP, Brazil
• Associated scholarship(s): 21/10169-9 - Expanding the possibilities of cryogenic assisted rectification: finite element heat transfer simulations, BP.TT; 21/11334-3 - Expanding the possibilities of cryogenically assisted grinding: training in instrumentation techniques and in the analysis of grinding test results, BP.TT; 21/02979-0 - Extending the possibilities of cryogenic assisted grinding: heat transfer simulation using finite element method (FEM), BP.TT

Abstract

In grinding operations, metal working fluids (MWF) are used to minimize the heat-associated problems such as surface cracks, burning, and tensile residual stresses. Filtration, recycling, and disposal of MWFs are additional cost factors. In response to eliminate the use of MWFs, the Brazilian research group has developed a method of dry grinding with precooled parts. In the method, a cryogenic medium is used to precool the part and subjected it to grinding operation without any MWF supply. However, the performance of the precooled parts in dry grinding depends on the shape, size, and dimensions of the part. Hence, in this collaborative project, investigations will be carried out to determine the advantages and disadvantages of the precooled parts in the dry grinding mode with a wide range of variables (different grinding processes, various workpiece dimensions), which were not given an attention so far. The German research group will focus on surface grinding, whereas the Brazilian research group will focus on cylindrical plunge grinding. To investigate the cooling method, both research groups will develop together a selection criteria and heat transfer simulations based on the part geometry, wheel and workpiece thermal properties to classify the suitable workpiece dimensions for a precooling method and in-situ partial precooling method (only a portion of the part is precooled). Based on simulation results, workpieces will be classified as large (not suitable for precooling method) and short (suitable for any cooling method), and accordingly, possible-cooling methods will be applied. A comprehensive knowledge on the capabilities of cryogenic application in grinding can be achieved. Ultimately, unrestricted exchange of the research results will lead to strengthen the relationship of this binational research group. (AU)