Novel comparison concept between CBN and Al2O3 grinding process for eco-friendly production

Author(s)

Sato, Bruno Kenta ^[1] ; Lopes, Jose Claudio ^[1] ; Rodriguez, Rafael Lemes ^[1] ; Garcia, Mateus Vinicius ^[1] ; Mia, Mozammel ^[2] ; Fonteque Ribeiro, Fernando Sabino ^[1] ; De Angelo Sanchez, Luiz Eduardo ^[1] ; Aguiar, Paulo Roberto ^[3] ; Bianchi, Eduardo Carlos ^[1]

Affiliation

^[1] Sao Paulo State Univ Unesp, Dept Mech Engn, BR-17033360 Bauru, SP - Brazil

^[2] Imperial Coll London, Dept Mech Engn, Exhibit Rd, London SW7 2AZ - England

^[3] Sao Paulo State Univ Julio de Mesquita Filho, Dept Elect Engn, Bauru, SP - Brazil

• Document type: Journal article
• Source: JOURNAL OF CLEANER PRODUCTION; v. 330, JAN 1 2022.
• Web of Science Citations: 0

Abstract

Minimal Quantity of Lubrication was developed to achieve green manufacturing in machining process. In this study, parameters of cutting fluid flow, grinding wheel type and wheel cleaning system were evaluated to achieve the maximum potential of this technique in grinding process. The comparison of super abrasive (CBN) and conventional (Al2O3) grinding wheel, the cutting fluid flow (30 ml/h, 60 ml/h and 120 ml/h), and the wheel cleaning system were analyzed based on: surface roughness, roundness errors, grinding wheel wear, confocal of grounded surface, grinding power, acoustic emission and workpiece microscopy. In a novel way, this study compared the costs per piece and the carbon footprint in terms of CO2 emission for both abrasive tool application. For all the parameters analyzed, the CBN grinding with MQL outperformed the Al2O3 grinding, showing a superior performance not only in terms of surface finishing, on average, 29% lower surface roughness and dimensional deviation 9% lower but also regarding tool efficiencies, such as 127% lower diametrical wear, 42% lower acoustic emission, and 13% lower grinding power. Despite that, the cost per piece was also evaluated for the different lubri-cooling conditions and tools, and the cost per piece recorded for Al2O3 grinding was substantially lower than CBN grinding, irrespective of the lubri-cooling method employed. The cost of grinding for all MQL techniques analyzed with aluminum oxide wheel was, on average, 72% less than grinding with CBN wheel. Besides, the conventional method with the CBN wheel was 7% more expensive than the aluminum oxide wheel. (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