Evaluating the optimized lubri-cooling technique for various cutting conditions in through-feed centerless grinding process

Abstract

The centerless grinding process is a fast and efficient process for precision batch and mass production grinding. This process employs wide wheels which allow substantial removal rates, and another additional advantage is that centers are not required as in center grinding. Wide wheels yield to lower wheel wear and higher accuracy for long periods, particularly when using in-process gauging. Many materials and parts of various shapes and sizes are produced by the centerless grinding, in particular, for bearing and automotive industries. In grinding process, the application of metal working fluid (MWF) in order to avoid thermal damages and excessive form deviation are indispensable. In this regard, this work aims to contribute to optimization of machining process through-feed by the study of centerless grinding process under the application of the optimized lubri-cooling technique by a novel multitubular nozzle for various cutting conditions. The multitubular nozzle was employed with emulsion (ME) and compressed air simultaneously (ME + CA) and with conventional nozzle (CN) application for a stock material removal (SMR) of 0.10 and 0.03 mm. All techniques were tested for three different flow rates: 10, 20, and 40 L/min. Surface roughness of the ground surface, roundness deviation, and SEM images of roundness deviation were analyzed. As a result, the ME + CA optimized application produced lower results than CN nozzles in general and the increase of surface roughness values is also produced by higher feed rate values which results in thicker chips in grinding process.