Contribution for minimization the usage of cutting fluids in CFRP grinding

Abstract

Composite materials are becoming essential and widely used in modern industry, mainly in aeronautics, aerospace, and naval sectors. The reason for its increasing use is their structural composition, a combination of two different materials, resulting in a low weight, extremely rigid, and resistant. Due to the material's anisotropy, it tends to present residual stresses or structural distortions. Recent researches show that the finishing machining process called grinding is the most recommended for eliminating these structural problems. In grinding process, there needs to be a great amount of cutting fluid (flood cooling), and the surface wear is high. The abundant application of these fluids has become a factor of concern for the modern industries, due to the issues related to occupational health and environmental hazard because of their toxic compounds. In reference to these concerns, arises a new methods of application as well the optimized cooling, the minimum quantity lubrication (MQL) technique and dry grinding. This way, this work analyzed the behavior of the surface grinding of carbon fiber reinforced plastic (CFRP) composites using optimized cooling, MQL, and dry cutting as an alternatives to the conventional coolant technique by SEM images of workpiece surface. Surface roughness, grinding force, specific grinding energy, and G ratio were also analyzed. SEM images showed the difference on fiber surface which is produced by the increase of the depth of cut and different lubrication methods adopted. With the results obtained, the MQL technique generated the lowest grinding values and grinding specific energy. The optimized and flood methods provided the lowest wear of the grinding wheel, as well as the better surface finishing.