Application of the Minimum Quantity Lubrication (MQL) Technique in the Plunge Cylindrical Grinding Operation

Abstract

Precision cylindrical grinding is used extensively in the manufacture of precision components in the metal-mechanical industry in general. Modern CNC grinding machines have improved this process with respect to the positioning and rigidity of the machine-workpiece-tool system, allowing the production of high precision parts with low dimensional tolerances. Besides the difficulties inherent to the process, awareness has grown in recent years regarding the environmental issues of cutting fluids. As a response, the industry has begun to seek alternative lubrication and cooling methods. Among the various existing techniques, Minimum Quantity Lubrication (MQL) has been considered as an alternative. This technique can be understood as a combination of conventional lubrication and cooling methods and dry machining, in which a small quantity of lubricating oil mixed with compressed air flow is delivered in the wheel-workpiece interface. The MQL technique is already widely employed in machining processes with tools of defined geometry (e. g. turning), in which produces very satisfactory results. However, the MQL technique has been little explored in grinding processes (non-defined tool geometry), in which the really effective heat removal methods are required due to the frictional heat generation in the grinding zone. Consequently, the aim of this study was to evaluate the plunge cylindrical internal grinding operation when using the MQL technique and the conventional cooling method. Roughness and roundness were the output parameters. As a result, it was found that the best values of roughness Ra were obtained with the conventional lubrication method. The MQL technique applied as proposed was not able to flush the chips away from the grinding zone, leading to the highest Ra values. No significant differences were detected among the cooling methods when analyzing the roundness results. The workpiece fixture method selected was responsible for the overall unsatisfactory results.