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Grinding comparative analysis between different proportions of water-oil applied to MQL technique and industrial production cost towards a green manufacturing

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Abstract

The high temperatures involved in the grinding process require an efficient lubri-refrigeration method. Currently, the conventional method (flood) is the most used in industries. However, this method comes up against environmental damage and the health of operators, due to high amounts of fluid injected into the cutting region. Therefore, the use of the minimum quantity lubricant (MQL) technique with a wheel cleaning jet (WCJ) proves to be a viable alternative. This work makes a comparative analysis of the MQL + WCJ system with a conventional method. In this sense, the experiments grinding the AISI 4340 steel with an aluminum oxide wheel. The lubrication and cooling of the process were done by the conventional method, pure MQL, and diluted MQL (oil-water 1:1, 1:3, 1:5) with and without cleaning (WCJ). The output parameters evaluated were surface roughness (Ra), roundness error, G-ratio, tangential cutting force, specific energy, microstructure, and cost. The surface roughness shows an increase of only 18%, with the use of the MQL technique diluted 1:5 + WCJ compared to the conventional method. Also, the implementation of the MQL technique is cheaper than the conventional method. The results show that the addition of water in MQL favors grinding, and the efficiency of MQL increases when associated with WCJ for all parameters.

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Acknowledgments

The authors also thank companies Norton Abrasives - Saint Gobain Group for providing the grinding wheel, ITW Chemical Products for the donation of the cutting fluids and Emuge-Franken for the donation of the vortex tube and the authors thank everyone by support to the research and opportunity for scientific and technological development.

Funding

The authors thank São Paulo Research Foundation (FAPESP) (process 2018/22661–2), CAPES (Coordination for the Improvement of Higher Level Education Personnel), and CNPq (National Council for Scientific and Technological Development) for their financial support of this research.

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Authors and Affiliations

  1. Department of Mechanical Engineering, São Paulo State UniSversity “Júlio de Mesquita Filho, Bauru campus, Bauru, São Paulo, Brazil

    José Claudio Lopes, Benício Nacif Ávila, Matheus de Souza Rodrigues, Mateus Vinicius Garcia, Hamilton José de Mello, Luiz Eduardo De Angelo Sanchez & Eduardo Carlos Bianchi

  2. Department of Control and Industrial Processes, Federal Institute of Paraná, Jacarezinho campus, Jacarezinho, Paraná, Brazil

    Fernando Sabino Fonteque Ribeiro

  3. Department of Electrical Engineering, São Paulo State University “Júlio de Mesquita Filho”, Bauru campus, Bauru, São Paulo, Brazil

    Paulo Roberto Aguiar

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  1. José Claudio Lopes
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Contributions

José Claudio Lopes: Writing - Original Draft; Writing - Review & Editing; Visualization; Conceptualization; Formal Analysis; Investigation; Validation.

Benício Nacif Ávila: Writing - Original Draft; Resources; Conceptualization; Methodology; Project administration.

Matheus de Souza Rodrigues: Writing - Original Draft; Writing - Review & Editing; Visualization; Conceptualization; Formal Analysis; Investigation; Validation.

Mateus Vinicius Garcia: Writing - Original Draft; Investigation; Data Curation; Formal analysis.

Fernando Sabino Fonteque Ribeiro: Conceptualization; Methodology; Validation; Writing – Original Draft.

Hamilton José de Mello: Conceptualization; Methodology; Formal Analysis; Investigation; Validation.

Luiz Eduardo de Angelo Sanchez: Writing - Review & Editing; Conceptualization; Supervision.

Paulo Roberto Aguiar: Software; Supervision.

Eduardo Carlos Bianchi: Funding acquisition; Conceptualization; Resources; Supervision; Project administration.

Corresponding author

Correspondence to Eduardo Carlos Bianchi.

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Lopes, J.C., Ávila, B.N., de Souza Rodrigues, M. et al. Grinding comparative analysis between different proportions of water-oil applied to MQL technique and industrial production cost towards a green manufacturing. Int J Adv Manuf Technol 113, 1281–1293 (2021). https://doi.org/10.1007/s00170-021-06625-2

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