Application of lubrication theory to optimise grinding fluid supply-surface integrity evaluation

Abstract

This paper describes an investigation about the grinding fluid optimization supply based on lubrication theory. The models for three-dimensional hydrodynamic flow pressure in contact zone between wheel and work were presented based on Navier- Stokes equation and continuous formulae. It is well known that hydrodynamic fluid pressure generates due to this fluid flux, and that it affects overall grinding resistance and machining accuracy. Moreover, conventional methods of delivering grinding fluid, i.e. flood delivery via a shoe or jet delivery tangential to the wheel via a nozzle, have been validated that can not fully penetrate this boundary layer and, thus, the majority of the cutting fluid is deflected away from the grinding zone. Therefore, in this paper, a new delivery method of grinding fluid that the minimum quantity lubricant (MQL) not only that reduces hydrodynamic lift force but also that reduces grinding fluid cost to achieved green manufacturing. Experiment was carried out to evaluate the performance of the MQL technology compared with conventional flood cooling. Experimental data indicate that the proposed method is not negatively affect the surface integrity.