Novel performance assessment of interrupted grinding process using aluminum oxide wheel with resinoid bond

Author(s)

Fonteque Ribeiro, Fernando Sabino ^[1] ; Lopes, Jose Claudio ^[2] ; Rodriguez, Rafael Lemes ^[2] ; de Angelo Sanchez, Luiz Eduardo ^[2] ; de Mello, Hamilton Jose ^[2] ; de Aguiar, Paulo Roberto ^[2] ; Bianchi, Eduardo Carlos ^[1]

Affiliation

^[1] Fed Inst Parana, Dept Control & Ind Proc, Jacarezinho Campus, Jacarezinho, Parana - Brazil

^[2] Sao Paulo State Univ Julio Mesquita Filho, Dept Mech Engn, Baum Campus, Bauru, SP - Brazil

• Document type: Journal article
• Source: INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY; v. 117, n. 9-10 AUG 2021.
• Web of Science Citations: 0

Abstract

The grinding of interrupted geometries, such as keyways, holes, lubrication channels and crankshafts, bearings, helical drills, sharpening, and gear hobbing process for pre-toothing, presents technical difficulties such as decrease in surface quality and an increase in costs, when compared to continuous grinding process. This work aims to study further findings about interrupted cylindrical grinding process of AISI 4340 steel, with the application of resinoid aluminum oxide grinding wheel and conventional application of MWF. In a novel and innovative way, this work analyzed the wheel wear cost at 3 different feed rates (0.25, 0.50, and 0.75 mm/min) for continuous workpieces and interrupted workpieces with 2, 6, and 12 grooves. In addition, surface roughness, roundness deviation, grinding power, tangential force, microstructural analysis, diametrical wear, and G ratio were also evaluated. In conclusion to the results obtained, the average values of surface roughness Ra and Rz increased with the severity of the process (feed rate and number of grooves). For feed rates varying from 0.25 to 0.75 mm/min, mean values of 0.51 to 1.10 mu m (Ra) and 4.52 to 10.99 mu m (Rz) were obtained for the condition with 12 interruptions, indicating an increase in the order of 75 to 114% compared to without interrupted workpiece. The quick wear of the wheel, obtained for an average diametrical wheel wear of 5.79 mu m for workpiece with 12 interruptions in 0.75 mm/min, produced higher surface roughness values. Variations of more than 80% in roundness deviation were obtained during grinding at feed rates of 0.75 mm/min due to mechanical shocks during material removal process, being observed in force variations from 50 to 700 N. The cost analysis of grinding wheel wear showed the waste of abrasive material for grinding process with interrupted geometries. For all tests, the tool cost for low feed rate (0.25 mm/min) did not suffer great variations. For feed rates of 0.50 and 0.75 mm/min, the cost of tool wear was higher. The condition with the highest percentage increase in cost was recorded for grinding process with workpiece of 12 grooves and feed rate of 0.75 mm/min, generating an increase of up to 1720% in the tool cost. Converting into monetary values, the wheel cost is of \$ 12.62 per 1000-piece batch. (AU)

• FAPESP's process: 18/22661-2 - Performance of the application of liquid nitrogen in the cylindrical grinding of the nickel alloy Inconel 718
• Grantee: Mateus Vinicius Garcia
• Support Opportunities: Scholarships in Brazil - Scientific Initiation
• FAPESP's process: 13/00551-7 - Milling of dies and moulds: vibration in the process and milling of complex profiles
• Grantee: Anselmo Eduardo Diniz
• Support Opportunities: Research Projects - Thematic Grants
• FAPESP's process: 15/09197-7 - Application of minimum of quantity of lubrification (MQL) during AISI 4340 steel cylyndrical grinding process
• Grantee: Rafael Lemes Rodriguez
• Support Opportunities: Scholarships in Brazil - Scientific Initiation