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Ghosh, Sudarsan
- Experimental Analysis of Brazed Diamond Dresser Using Single Grit Scratch on Zirconia Ceramic
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1 Indian Institute of Technology Delhi, New Delhi, India., IN
1 Indian Institute of Technology Delhi, New Delhi, India., IN
Source
Manufacturing Technology Today, Vol 22, No 4 (2023), Pagination: 8-13Abstract
The overall performance of the grinding wheel is difficult to analyze, as it is a compilation of individual abrasive grit contributions. The single grit scratch test is useful to investigate the effect of the individual grit effect on the work material. A vacuum-brazed diamond dresser is developed for the single grit scratch experiment. Partially stabilized zirconia is used as work material to study the mechanics of material removal and mode of grit failure. The experiments were performed in dry conditions by varying the wheel speed, table feed, and depth of cut. The grit failure mechanism has been analyzed using a scanning electron microscope image and correlated with the induced force during the scratch test. The results show that the diamond microcracking was observed after 370 mm of grinding scratch marks. And the maximum tangential and normal force withstand by the diamond grit is 13.09 N and 19.65N, respectively.Keywords
Single Grit Scratch, Ceramics, Force Analysis.References
- Anand, P., Arunachalam, N., & Vijayaraghavan, L. (2019). Evaluation of grinding strategy for bioceramic material through a single grit scratch test using force and acoustic emission signals. Journal of Manufacturing Processes, 37, 457-469. https://doi.org/10.1016/j.jmapro.2018.12.006
- Buhl, S., Leinenbach, C., Spolenak, R., & Wegener, K. (2013). Failure mechanisms and cutting characteristics of brazed single diamond grains. International Journal of Advanced Manufacturing Technology, 66(5-8), 775-786. https://doi.org/10.1007/s00170-012-4365-z
- Denkena, B., Wippermann, A., Busemann, S., Kuntz, M., & Gottwik, L. (2018). Comparison of residual strength behavior after indentation, scratching and grinding of zirconia-based ceramics for medical-technical applications. Journal of the European Ceramic Society, 38(4), 1760-1768. https://doi.org/10.1016/j. jeurceramsoc.2017.11.042
- Denry, I., & Kelly, J. R. (2008). State of the art of zirconia for dental applications. Dental Materials, 24(3), 299-307. https://doi.org/10.1016/j. dental.2007.05.007
- Flanders, L. A., Quinn, J. B., Wilson, O. C., & Lloyd, I. K. (2003). Scratch hardness and chipping of dental ceramics under different environments. Dental Materials, 19(8), 716-724. https://doi. org/10.1016/S0109-5641(03)00018-6
- Lee, S. K., Tandon, R., Readey, M. J., & Lawn, B. R. (2000). Scratch damage in zirconia ceramics. Journal of the American Ceramic Society, 83(6), 1428-1432. https://doi. org/10.1111/j.1151-2916.2000.tb01406.x
- Matsuo, T., Toyoura, S., Oshima, E., & Ohbuchi, Y. (1989). Effect of Grain Shape on Cutting Force in Superabrasive Single-Grit Tests. CIRP Annals - Manufacturing Technology, 38(1), 323-326. https://doi.org/10.1016/S0007-8506 (07)62714-0
- Naskar, A., Choudhary, A., & Paul, S. (2020). Wear mechanism in high-speed superabrasive grinding of titanium alloy and its effect on surface integrity. Wear, 462-463(September), 203475. https://doi.org/10.1016/j.wear.2020.203475
- Ohbuchi, Y., & Matsuo, T. (1991). Force and Chip Formation in Single-Grit Orthogonal Cutting with Shaped CBN and Diamond Grains. CIRP Annals - Manufacturing Technology, 40(1), 327-330. https://doi.org/10.1016/S0007-8506 (07)61998-2
- Study on Atomization Characteristics of Droplet of Bio-Degradable Oil for End-Milling of Incoloy 925
Abstract Views :51 |
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Authors
Affiliations
1 Indian Institute of Technology Delhi, New Delhi, India., IN
1 Indian Institute of Technology Delhi, New Delhi, India., IN
Source
Manufacturing Technology Today, Vol 22, No 4 (2023), Pagination: 45-51Abstract
Minimum Quantity Lubrication (MQL) has been proved as an effective technique of lubrication and cooling in machining. However, evacuation of cutting temperature depends on the lubricant’s droplet quality, which is highly influenced by MQL setup parameters. This paper aims to study the effects of nozzle angle, nozzle distance, flow rate, and air pressure on the end milling performance of Incoloy 925. Orthogonal array (L9) is used for the design of experiments, and the influence of MQL parameters is analysed by ANOVA. Response surface methodology (RSM) has been used for a linear regression model, and Composite Desirability function has been utilized for optimization of parameters. ANOVA shows that flow rate has highest influence on both cutting force and surface roughness. Nozzle angle is having lowest influence on cutting force, while stand-off distance has the lowest influence on the surface roughness.Keywords
MQL, Coconut Oil, Incoloy 925, End-Milling, RSM.References
- Awale, A. S., Vashista, M., Zaheer, M., & Yusufzai, K. (2020). Multi-objective optimization of MQL mist parameters for eco-friendly grinding. Journal of Manufacturing Processes, 56(April), 75-86. https://doi.org/10.1016/j. jmapro.2020.04.069
- Cardoso, L. G., Madeira, D. S., Ricomini, T. E. P. A., Miranda, R. A., Brito, T. G., & Paiva, E. J. (2021). Optimization of machining parameters using response surface methodology with desirability function in turning duplex stainless steel UNS S32760. International Journal of Advanced Manufacturing Technology, 117(5-6), 1633-1644.https://doi.org /10.1007/s00170-021-07690-3
- Du, F., He, L., Zhou, T., Tian, P., Zou, Z., & Zhou, X. (2022). Analysis of droplet characteristics and cooling lubrication effects in MQL milling of 316L stainless steel. Journal of Materials Research and Technology, 19, 4832-4856. https://doi. org/10.1016/J.JMRT.2022.06.132
- Emami, M., Sadeghi, M. H., & Sarhan, A. A. D. (2013). Investigating the effects of liquid atomization and delivery parameters of minimum quantity lubrication on the grinding process of Al2O 3 engineering ceramics. Journal of Manufacturing Processes, 15(3), 374-388. https://doi.org/10.1016/j.jmapro.2013.02.004
- Hsiao, T. C., Vu, N. C., Tsai, M. C., Dang, X. P., & Huang, S. C. (2020). Modeling and optimization of machining parameters in milling of INCONEL-800 super alloy considering energy, productivity, and quality using nanoparticle suspended lubrication. Measurement and Control (United Kingdom). https://doi. org/10.1177/0020294020925842
- INCOLOY alloy 925. (2002). Special Metals. https:// cdn2.hubspot.net/hubfs/483909/Corrotherm-Oct2016-Theme/PDF Files/Incoloy925.pdf
- Jayadas, N. H., & Nair, K. P. (2006). Coconut oil as base oil for industrial lubricants-evaluation and modification of thermal, oxidative and low temperature properties. Tribology International, 39(9), 873-878. https://doi.org/10.1016/j. triboint.2005.06.006
- Khan, M. M. A., Mithu, M. A. H., & Dhar, N. R. (2009). Effects of minimum quantity lubrication on turning AISI 9310 alloy steel using vegetable oil-based cutting fluid. Journal of Materials Processing Technology, 209 (15-16), 5573-5583. https://doi.org/10.1016/j. jmatprotec.2009.05.014
- Khidhir, B. A., Al-Oqaiel, W., & Kareem, P. (2015). 1-6Prediction Models by Response Surface Methodology for Turning Operation. American Journal of Modeling and Optimization, 3(1), 1-6. https://doi.org/10.12691/ajmo-3-1-1
- Park, K. H., Olortegui-Yume, J., Yoon, M. C., & Kwon, P. (2010). A study on droplets and their distribution for minimum quantity lubrication (MQL). International Journal of Machine Tools and Manufacture, 50(9), 824-833. https://doi. org/10.1016/J.IJMACHTOOLS.2010.05.001
- Safiei, W., Rahman, M. M., & Rusdan, S. A. (2018). Experimental investigation of MQL optimum parameters in end milling of AA6061-T6 using Taguchi method. International Journal of Engineering and Technology(UAE), 7(4), 186-189. https://doi.org/10.14419/ijet.v7i4.35.22360
- Sun, H., Zou, B., Chen, P., Huang, C., Guo, G., Liu, J., Li, L., & Shi, Z. (2022). Effect of MQL condition on cutting performance of high-speed machining of GH4099 with ceramic end mills. Tribology International, 167, 107401. https:// doi.org/10.1016/J.TRIBOINT.2021.107401
- Tawakoli, T., Hadad, M. J., & Sadeghi, M. H. (2010). Influence of oil mist parameters on minimum quantity lubrication – MQL grinding process. International Journal of Machine Tools and Manufacture, 50(6), 521-531. https://doi. org/10.1016/J.IJMACHTOOLS.2010.03.005