Aplicação sustentável de diferentes técnicas de lubrirrefrigeração no processo de retificação de cerâmica avançada
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Data
2023-02-17
Autores
Talon, Anthony Gaspar
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Universidade Estadual Paulista (Unesp)
Resumo
Existe uma crescente demanda por projetos com materiais que serão utilizados em aplicações inertes, onde nenhuma reação física ou química pode interagir com os elementos ao seu redor. Juntamente com a demanda desses projetos, surge a necessidade de estudar os processos de fabricação desses materiais. Nesse sentido, um novo conceito de processo de fabricação precisa ser explorado, pois os estudos sobre aplicações cerâmicas avançadas como elementos internos de motores, estruturas aeronáuticas, sensores, supercondutores, capacitores e principalmente como biomateriais aplicados como próteses e órteses pela medicina, começam a ganhar espaço. No entanto, ainda faltam estudos sobre os processos de fabricação em larga escala desses produtos, principalmente relacionados à sua retificação. Portanto, é fundamental estudar as melhores formas de processamento de materiais que serão essenciais para as indústrias mecânica, eletrônica e biológica em um futuro próximo. Além disso, estudos sobre cerâmicas avançadas têm se tornado cada vez mais indispensáveis, baseados em fatores como alto valor agregado devido à dificuldade de fabricação aliada ao alto impacto ambiental causado por este processo. No entanto, as cerâmicas avançadas são materiais de difícil usinagem devido às suas propriedades de alta dureza e fragilidade, tornando necessários processos de fabricação mais complexos, como a retificação. Portanto, este trabalho explorou diversas condições aplicadas à cerâmica avançada, abordando as principais variáveis utilizadas pelas indústrias mundiais, sendo elas: rugosidade (Ra), desvio de circularidade, desgaste diametral do rebolo, razão G, potência de retificação e análise de custos do processo. O processo de retificação utilizado na pesquisa foi do tipo cilíndrica externa de mergulho utilizando um rebolo diamantado aplicado a quatro diferentes velocidades de avanço: 0,25, 0,50, 0,75 e 1,00 mm/min. Além disso, foram utilizados dois sistemas de aplicação de fluido de corte no processo: técnicas de lubrificação convencional e MQL, com vazão de 15 l/min e 100 ml/h, respectivamente. Os resultados indicaram que o MQL gerou uma perda de qualidade nas variáveis de saída e apresentou custos mais elevados ao processo. Nesse sentido, o MQL não se mostra como uma alternativa viável para a retificação de cerâmicas com rebolo de diamante.
The growing demand for current and future projects lacks materials development and their manufacturing process, mainly when they need to be used in inert applications, where no physical or chemical reaction can interact with the elements around them. In this sense, a new manufacturing process concept needs to be explored because studies about advanced ceramic applications as internal elements to engines, aeronautical structures, sensors, superconductors, capacitors and mainly as biomaterials applied as prostheses and orthotics by medicine begin to gain space. However, there is still a lack of studies on the large-scale manufacturing processes of these products, mainly related to their grinding. Therefore, it is crucial to study the best ways of processing materials that will be essential to the mechanical, electronic and biological industries in the near future. Furthermore, studies about advanced ceramics have become increasingly indispensable, based on factors such as high added values due to the difficulty of manufacturing combined with the high environmental impact caused by this process. However, advanced ceramics are materials with difficult to machine because of their high hardness and fragility properties, becoming required manufacturing processes more complex, such as grinding. Therefore, this paper explored several conditions applied to advanced ceramic, approaching the main variables used by worldwide industries, being: surface roughness (Ra), roundness error, diametral wheel wear, Razão G, grinding power and analysis costs process. The grinding process used in the research was of kind plunge combined to a diamond wheel applied to four different feed rates: 0.25, 0.50, 0.75 and 1.00 mm/min, in which two systems by application of cutting fluid in the process were also used: flood and MQL lubri-refrigeration techniques, with a flow rate of 15 l/min and 100 ml/h, respectively. The results indicated that the MQL generated a loss of quality in the output variables and presented higher costs to the process. In this sense, the MQL does not appear to be a viable alternative for grinding ceramics with diamond grinding wheels.
The growing demand for current and future projects lacks materials development and their manufacturing process, mainly when they need to be used in inert applications, where no physical or chemical reaction can interact with the elements around them. In this sense, a new manufacturing process concept needs to be explored because studies about advanced ceramic applications as internal elements to engines, aeronautical structures, sensors, superconductors, capacitors and mainly as biomaterials applied as prostheses and orthotics by medicine begin to gain space. However, there is still a lack of studies on the large-scale manufacturing processes of these products, mainly related to their grinding. Therefore, it is crucial to study the best ways of processing materials that will be essential to the mechanical, electronic and biological industries in the near future. Furthermore, studies about advanced ceramics have become increasingly indispensable, based on factors such as high added values due to the difficulty of manufacturing combined with the high environmental impact caused by this process. However, advanced ceramics are materials with difficult to machine because of their high hardness and fragility properties, becoming required manufacturing processes more complex, such as grinding. Therefore, this paper explored several conditions applied to advanced ceramic, approaching the main variables used by worldwide industries, being: surface roughness (Ra), roundness error, diametral wheel wear, Razão G, grinding power and analysis costs process. The grinding process used in the research was of kind plunge combined to a diamond wheel applied to four different feed rates: 0.25, 0.50, 0.75 and 1.00 mm/min, in which two systems by application of cutting fluid in the process were also used: flood and MQL lubri-refrigeration techniques, with a flow rate of 15 l/min and 100 ml/h, respectively. The results indicated that the MQL generated a loss of quality in the output variables and presented higher costs to the process. In this sense, the MQL does not appear to be a viable alternative for grinding ceramics with diamond grinding wheels.
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Palavras-chave
Retificação, Cerâmicas, Diamante, Grinding, Diamond wheel, Advanced ceramic, MQL