Utilização de diferentes métodos de lubri-refrigeração na retificação cilíndrica externa de mergulho de cerâmica avançada com rebolo diamantado
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Data
2012-02-03
Autores
Simões, Rafael Plana [UNESP]
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Universidade Estadual Paulista (Unesp)
Resumo
Atualmente há por parte das empresas uma constante preocupação com a atualidade de seus sistemas produtivos, buscando a melhoria da eficiência dos processos respeitando as leis de preservação ambiental. Dentro desse contexto e considerando que o segmento das cerâmicas corresponde a aproximadamente 1% do PIB brasileiro, com perspectiva de crescimento, inúmeros estudos têm sido feitos nesse campo de pesquisa. Contudo, ainda se tem um alto custo agregado ao acabamento da peça, o qual é feito, na maioria dos casos, pelo processo de retificação. Além do alto custo do processamento, o uso de fluidos de corte tem se tornado um problema para a indústria devido à dificuldade de descarte imposta pela rígida Legislação Ambiental. Face ao exposto, o presente trabalho propõe o estudo de métodos alternativos de lubri-refrigeração para o processo de retificação externa de mergulho de cerâmica avançado com rebolo diamantado. Tais métodos visam diminuir os gastos com fluido de corte, sendo eles: a técnica de lubri-refrigeração otimizada e a de mínima quantidade de lubrificação (MQL). A avaliação das técnicas foi feita através do monitoramento do processo e da quantidade final da peça retificada. Mais especificamente, foram analisados: força tangencial de corte, rugosidade, relação G, desvio de circularidade, microestrutura e tensão residual por difração de raios X. Os resultados obtidos mostram que as duas técnicas propostas podem substituir o método convencional de lubri-refrigeração, destacando-se que a técnica otimizada reduziu o desgaste do rebolo e produziu pelas com melhor acabamento geométrico e dimensional, enquanto a técnica de MQL reduziu significativamente a quantidade de fluido utilizado no processo
During the last years there has been a constant concern by the companies about the modernization of their manufacturing methods, seeking to improve the process efficiency and environmental preservation. In this context, and considering the ceramic segment corresponds to approximatelly 1% of Brazilian GDP, with growing perspective, many studies have been done in this area. Nevertheless, the work piece finishing is still expensive, mainly because it has been usually made by the grinding process. Besides of the high cost of the process, the use of cutting fluids has become a problem for the industry because of the discard dificulty imposed by the rigorous environmental laws. In this way, the present work proposes alternative methods for the lubrification and cooling in the external cylindrical plunge grinding of advanced ceramic with diamond wheels, which aims to reduce the costs with cutting fluid. These methods are: the optimized cooling and the Minimal Quantity Lubrication (MQL) techniques. The evaluation of these techniques has been made by the process monitoring and the work piece final quality. In the present work the following analysis techniques were used: tangential cut force, roughness, G relation, circularity deviation, microstructure and residual stress by X ray diffraction measurements. The results show both proposed techniques can replace the conventional cooling method. The main result is that the optimized technique reduced the cutting tool consuming and produced work pieces with better dimensional finishing, while the MQL techniques significantly reduced the volume of cutting fluid in the process
During the last years there has been a constant concern by the companies about the modernization of their manufacturing methods, seeking to improve the process efficiency and environmental preservation. In this context, and considering the ceramic segment corresponds to approximatelly 1% of Brazilian GDP, with growing perspective, many studies have been done in this area. Nevertheless, the work piece finishing is still expensive, mainly because it has been usually made by the grinding process. Besides of the high cost of the process, the use of cutting fluids has become a problem for the industry because of the discard dificulty imposed by the rigorous environmental laws. In this way, the present work proposes alternative methods for the lubrification and cooling in the external cylindrical plunge grinding of advanced ceramic with diamond wheels, which aims to reduce the costs with cutting fluid. These methods are: the optimized cooling and the Minimal Quantity Lubrication (MQL) techniques. The evaluation of these techniques has been made by the process monitoring and the work piece final quality. In the present work the following analysis techniques were used: tangential cut force, roughness, G relation, circularity deviation, microstructure and residual stress by X ray diffraction measurements. The results show both proposed techniques can replace the conventional cooling method. The main result is that the optimized technique reduced the cutting tool consuming and produced work pieces with better dimensional finishing, while the MQL techniques significantly reduced the volume of cutting fluid in the process
Descrição
Palavras-chave
Ceramica - Acabamento, Ceramica - Retificação e polimento, Técnicas de lubri-refrigeração, Retificação cilíndrica externa de mergulho, External cylindrical plunge grinding, Lubrication and cooling techniques
Como citar
SIMÕES, Rafael Plana. Utilização de diferentes métodos de lubri-refrigeração na retificação cilíndrica externa de mergulho de cerâmica avançada com rebolo diamantado. 2012. 159 f. Tese (doutorado) - Universidade Estadual Paulista, Faculdade de Ciências, 2012.