MATERIAL REMOVAL RATE AND SURFACE ROUGHNESS ON GRINDING OF DUCTILE CAST IRON USING MINIMUM QUANTITY LUBRICATION
DOI:
https://doi.org/10.15282/ijame.11.2015.27.0208Keywords:
Minimum quantity lubrication, Grinding, Material removal rate, Surface roughness, Cast ironAbstract
A promising alternative to conventional fluid coolant application is minimum quantity lubrication (MQL). Despite much research, there have been few investigations about the influence of MQL parameters on the process results, such as oil flow rate, workpiece speed and depth of cut. The objective of this project is to develop a mathematical model of the material removal rate and surface roughness on grinding of ductile cast iron using minimum quantity lubrication. The experiment was carried out according to the design of experiment principle, prepared based on central composite design. The experimental data was utilized to develop the mathematical model for first- and second-order models. The second order gives acceptable performance of the grinding. The result shows that the highest value of the grinding ratio is with single-pass MQL, and the lowest value is with multiple-pass conventional coolants. The model fit was adequate and acceptable for sustainable grinding using a 0.15% volume concentration of ethylene glycol. This paper quantifies the impact of water-based ethylene glycol on the surface quality achieved. It is concluded that the surface quality is most influenced by the depth of cut and table speed. It is recommended that future research is also conducted using another parameter such as the speed of the grinding wheel or the distance from the wheel– workpiece contact zone. Besides that, further research can be conducted using different nozzle angles and different types of grinding wheel to see how these affect the surface of the material.
References
[1] Rahman MM, Kadirgama K, Ab Aziz AS. Artificial neural network modeling of grinding of ductile cast iron using water based SiO2 nanocoolant. International Journal of Automotive and Mechanical Engineering. 2014;9:1649-61.
[2] Shen B, Xiao G, Guo C, Malkin S, Shih AJ. Thermocouple fixation method for grinding temperature measurement. Journal of Manufacturing Science and Engineering. 2008;130:051014.
[3] Shaji S, Radhakrishnan V. Analysis of process parameters in surface grinding with graphite as lubricant based on the Taguchi method. Journal of Materials Processing Technology. 2003;141:51-9.
[4] Shen B, Shih AJ. Minimum quantity lubrication (MQL) grinding using vitrified CBN wheels. Trans NAMRI/SME. 2009;37:129-36.
[5] Tawakoli T, Hadad M, Sadeghi M, Daneshi A, Stöckert S, Rasifard A. An experimental investigation of the effects of workpiece and grinding parameters on minimum quantity lubrication—MQL grinding. International Journal of Machine Tools and Manufacture. 2009;49:924-32.
[6] Khan MAR, Rahman MM, Kadirgama K, Maleque MA, Ishak M. Prediction of surface roughness of Ti-6Al-4V in electrical discharge machining: A regression model. Journal of Mechanical Engineering and Sciences. 2011;1:16-24.
[7] Abu Bakar MH, Raja Abdullah RI, Md. Ali MA, Kasim MS, Sulaiman MA, Ahmad SSN, et al. Surface integrity of LM6 aluminum metal matrix composite when machined with high speed steel and uncoated carbide cutting tools. Journal of Mechanical Engineering and Sciences. 2014;6:854-62.
[8] Hamdan SH, Md Said AY, Biki JR. Surface finish when threading titanium- based alloy under dry machining. Journal of Mechanical Engineering and Sciences. 2014;7:1062-9.
[9] Tawakoli T, Westkaemper E, Rabiey M, Rasifard A. Influence of the type of coolant lubricant in grinding with CBN tools. International Journal of Machine Tools and Manufacture. 2007;47:734-9.
[10] Najiha MS, Rahman MM, Kamal M, Yusoff AR, Kadirgama K. Minimum quantity lubricant flow analysis in end milling processes: A computational fluid dynamics approach. Journal of Mechanical Engineering and Sciences. 2012;3:340-5.
[11] Najiha MS, Rahman MM. A Computational Fluid Dynamics Analysis of Single and Three Nozzles Minimum Quantity Lubricant Flow for Milling. International Journal of Automotive and Mechanical Engineering. 2014;10:1891-900.
[12] Oliveira J, Alves SM. Development of environmentally friendly fluid for CBN grinding. CIRP Annals-Manufacturing Technology. 2006;55:343-6.
[13] Najiha MS, Rahman MM, Yusoff AR, Kadirgama K. Investigation of flow behavior in minimum quantity lubrication nozzle for end milling processes. International Journal of Automotive and Mechanical Engineering. 2012;6:768- 76.
[14] Puvanesan M, Rahman MM, Najiha MS, Kadirgama K. Experimental investigation of minimum quantity lubrication on tool wear in aluminum alloy 6061-t6 using different cutting tools. International Journal of Automotive and Mechanical Engineering. 2014;9:1538-49.
[15] Silva L, Bianchi E, Catai R, Fusse R, Franca T, Aguiar P. Study on the behavior of the minimum quantity lubricant-MQL technique under different lubricating and cooling conditions when grinding ABNT 4340 steel. Journal of the Brazilian Society of Mechanical Sciences and Engineering. 2005;27:192-9.
[16] Hollis JM, Lovas FJ, Jewell PR, Coudert L. Interstellar antifreeze: ethylene glycol. The Astrophysical Journal Letters. 2002;571:L59.
[17] Boersma BJ. A 6th order staggered compact finite difference method for the incompressible Navier–Stokes and scalar transport equations. Journal of Computational Physics. 2011;230:4940-54.
[18] Myers RH, Montgomery DC, Anderson-Cook CM. Response surface methodology: process and product optimization using designed experiments: John Wiley & Sons; 2009.
Downloads
Published
Issue
Section
License
Copyright (c) 2015 The Author(s)
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
