Advances in Engineering Advances in Engineering features breaking research judged by Advances in Engineering advisory team to be of key importance in the Engineering field. Papers are selected from over 10,000 published each week from most peer reviewed journals.
Significance Statement
In recent decades, with increasing awareness of sustainable manufacturing, there has been rising demand for the development of environmental-friendly and energy-conserving manufacturing technologies. The concept of minimum quantity lubrication (MQL), which refers to the use of cutting fluids of only a minute amount, has been suggested two decades ago as a means of addressing the environmental and economical issues. The minimization of cutting fluids not only alleviates environmental impact but also leads to economical benefits by ways of saving lubricant cost and workpiece/tool/machine cleaning cycle time. While extensive research has been conducted in various cutting processes such as turning, milling and drilling, minimum quantity lubrication grinding is still a relatively new research area that requires more comprehensive analysis. Our research presents detailed profiling of minimum quantity lubrication grinding capability in terms of grinding force, temperature distribution and surface finish and provides a theoretical understanding of the process. The research outputs has a great potential in industrial applications for advancing the minimum quantity lubrication technology into manufacturing practice.
Journal Reference
Yamin Shao1, Beizhi Li 2, Kuo-Ning Chiang 3, Steven Y. Liang 1
[expand title=”Show Affiliations”]- George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, 813 Ferst Dr. Rm. 211, Atlanta, GA, 30332-0560, USA
- College of Mechanical Engineering, Donghua University, 2999 North Renmin Rd., Songjiang District, Shanghai, 201620, China
- Department of Power Mechanical Engineering, National Tsing Hua University, 101 Section 2, Kuang-Fu Road, Hsinchu, 30013, Taiwan [/expand]
Abstract
Minimum quantity lubrication (MQL), which is to apply a minimum amount of lubricant directly into the contact zone, is a promising alternative to substantially reduce the lubricant cost caused by conventional flood cooling. In order to advance the minimum quantity lubricationtechnique into grinding situations, understanding of the process and evaluation of the performance is necessary. Most documented studies thus far concerning minimum quantity lubrication grinding are built upon experimental observations with individual and separate treatment of grinding performance measures such as grinding force, temperature, wheel wear, and surface roughness. This paper develops the analytical understanding of mechanical and thermal effects of minimum quantity lubrication in grinding and profiles the minimum quantity lubrication performance as functions of process and fluid application parameters. Physics-based predictive models are formulated to quantitatively describe the grinding force considering the lubrication effect of minimum quantity lubrication. The friction coefficient under minimum quantity lubrication condition is first predicted based on boundary lubrication theory, followed by the single grit force and grit distribution analysis. Further, surface roughness is calculated from the results of undeformed chip thickness distribution through probabilistic analysis. Additionally, energy partition and temperature distribution in the workpiece have been developed based on the moving heat source model. Material constitutive model are utilized to capture the influence of temperature and strain rate on the material flow stress. Experimental measurements of force, temperature, and surface roughness have also been pursued to calibrate and validate the predictive models.
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