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Research Papers

The Influence of Cutting Fluid Concentration on Surface Integrity of VP80 Steel and the Influence of Cutting Fluid Flow Rate on Surface Roughness of VPATLAS Steel After Grinding

[+] Author and Article Information
Raphael Lima de Paiva

Department of Mechanical Engineering,
Federal University of Piauí,
Campus Universitário Ministro Petrônio Portella,
Ininga,
Teresina 64049-550, PI, Brazil
e-mail: raphaellimap@hotmail.com

Rosemar Batista da Silva

Department of Mechanical Engineering,
Federal University of Uberlândia,
Av. João Naves de Ávila,
Santa Mônica,
Uberlândia 2121, MG, Brazil
e-mail: rosemar.silva@ufu.br

Mark J. Jackson

Mechanical Engineering Technology,
Kansas State University,
Polytechnic Campus,
2310 Centennial Road,
Salina, KS 67401-8196
e-mail: mjjackson@ksu.edu

Alexandre Mendes Abrão

Department of Mechanical Engineering,
Universidade Federal de Minas Gerais,
Av. Pres. Antônio Carlos 6627,
Pampulha,
Belo Horizonte 31270-901, MG, Brazil
e-mail: abrao@demec.ufmg.br

Manuscript received March 13, 2017; final manuscript received October 5, 2017; published online November 2, 2017. Assoc. Editor: Xun Chen.

J. Manuf. Sci. Eng 139(12), 121003 (Nov 02, 2017) (7 pages) Paper No: MANU-17-1145; doi: 10.1115/1.4038149 History: Received March 13, 2017; Revised October 05, 2017

The application of cutting fluid in grinding operations is crucial to control temperature levels and prevent thermal damage to the workpiece. Water-based (emulsions and solutions) coolants are used in grinding operations owing to their excellent cooling capability and relatively lower cost compared to neat oils. However, the cutting fluid efficiency is not only dependent on its type, but also on other parameters including its concentration and flow rate. In this context, this work aims to analyze the influence of the coolant concentration and flow rate on the grinding process. Two different workpiece materials for the production of plastic injection moulds were machined: VP80 and VPATLAS steel grades. Six grinding conditions (combinations of depth of cut values of 5, 15, and 25 μm with coolant concentration of 3% and 8%, respectively) were employed in the former, while two grinding conditions were used for the latter. The output parameter used to assess the influence of coolant concentration and flow rate on the grinding operation focused on the integrity of the workpiece materials (surface roughness and microhardness below the ground surface). The results showed that the surface integrity of VP80 after grinding was more sensitive to depth of cut than to cutting fluid concentration. Furthermore, the highest coolant concentration outperformed the lowest one when grinding under more severe conditions. With regard VPATLAS steel, no influence of the coolant flow rate on surface roughness was observed.

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Figures

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Fig. 1

Set up for the experimental trials: (a) peripheral surface grinding machine; (b) abrasive wheel; (c) dimensions (mm) of the VP80 steel; (d) dimensions (mm) of the VPATLAS steel

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Fig. 2

Surface roughness of VP80 steel as a function of depth of cut (ae) and different coolant concentrations

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Fig. 3

Effect on the Ra parameter of VP80 steel when: (a) increasing cutting fluid concentration from 3% to 8% for each depth of cut used; (b) increasing radial depth of cut from 5 μm to 25 μm for each cutting fluid concentration used

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Fig. 4

Hardness variation in VP80 steel grade after machining with: (a) ae = 5 μm, (b) ae = 15 μm, and (c) ae = 25 μm

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Fig. 5

Surface plot of the regression model for surface roughness (Ra parameter) after machining VP80 steel grade with different cutting conditions

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Fig. 6

Surface plot of the regression model for microhardness 5 μm below machined surface after machining VP80 steel grade with different cutting conditions (h5)

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Fig. 7

Surface roughness of VPATLAS after grinding as a function of cutting fluid flow rate

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