The paper presents a study of the process of grinding titanium grinding wheels with
mikrokorundu, sanding at surfaces involving liquid - cooling lubricants using MQL,
used machining  fluid - propylene glycol and other liquids business dedicated to the administration with a minimum expenditure of the grinding zone. Were studied component of cutting forces - and tangent parameter

Wejman, Przemysław

Wójcik, Ryszard

English

Lodz University of Technology Repository

Mechanics and Mechanical EngineeringVol. 20, No. 3 (2016) 255{261c Lodz University of TechnologyGrinding Process Results with Oil MistRyszard WojcikPrzemys law WejmanInstitute of Machine Tools and Production EngineeringLodz University of TechnologyStefanowskiego 1/15,  Lodz, Polandryszard.wojcik@p.lodz.plprzemyslaw.wejman@gmail.comReceived (20 February 2016)Revised (26 February 2016)Accepted (11 April 2016)The paper presents a study of the process of grinding titanium grinding wheels withmikrokorundu, sanding at surfaces involving liquid - cooling lubricants using MQL,used machining uid - propylene glycol and other liquids business dedicated to the ad-ministration with a minimum expenditure of the grinding zone. Were studied componentof cutting forces - and tangent parameter.Keywords: grinding, titanium alloys, lubrication with a minimum amount of oil.1. IntroductionThe cutting of the titanium alloys depends on their chemical composition. Es-pecially the increased content of oxygen, hydrogen and carbon has unfavorableinuence on their machinability.The predisposition of this type of alloys to a reaction with surroundings in raisedtemperatures is a generally well{known fact [1, 2, 3]. The wear of the grinding wheelmakes the grinding process of titanium alloys dicult, because it inuences: the in-crease of temperature, low smoothness of the surface and structural transformationsin the material.Abrasive tools with a larger resistance to wear are still sought after. The re-generation of active surfaces of such grinding wheels should be identical, as in con-ventional ones [5], because they can be regenerated easily, especially in individualproduction or small lot production. The grinding wheels of the super{hard group [4,14] require special and specic methods of regeneration. Studies of grinding wheelsfrom TGP, XGP (the microcrystalline corundum) group are also being conducted.256 Wojcik, R. and Wejman, P.2. Conditions the studiesThe aim of the investigation was to analyze the inuence of chosen grinding wheelsand cutting cooling lubricants on the grinding forces, the grinding energy indicatorand the quality of the surface. The usefulness of the cutting uids was testedwith a view to selecting the appropriate cooling and lubricating conditions whichwill guarantee the desired roughness of the surface and will not allow excessivedeformations of the thinner elements.The experiments were conducted for three titanium alloys: Ti-6Al-4V and TIGER5. The chemical composition of the alloys is presented in Tab. 1. The analysis ofthe alloys was conducted with the quantometer ARL 360.Table 1 The chemical composition of the titanium alloysSIGN ALLOYCHEMICAL ANALYSIS, %Al C Fe H N V O Mo TiP Ti-6Al-4 6.12 0.65 0.22 00.02 0.52 4.17 0.12 - RT TIGER 5 6.51 0.23 0.15 0.002 0.01 4.4 0.13 - RThe rst part of the investigations concerns only Tiger 5 and Ti -6Al-4 alloys,which were ground with the usage of propylene glycol - symbol (GP). The results re-ceived from grinding with commercial grinding uids applied in conventional grind-ing were compared with propylene glycol. The trade names of the liquids are :(MC) - Micro 3000, (EC) - EcoCut micro 82, (BO) 3000. The samples were groundby grinding wheels with microcorundum TGP and XGP.The grinding uid, in the form of oil fog under a pressure of 0,6MPa, at aquantity of 50ml/hour, was applied through a nozzle to the sample surface. Thedistance of the nozzle to the sample surface was 4mm, at an inclination angle of250.To measure the grinding forces a dynamometer 9272 was used, on which a griphandle with a sample was mounted. The signal from the dynamometer was sent toan amplier 5011A and cardDAS 1602, which was placed in a computer. The station, together with thesoftware was described in articles [11, 12].The smallest values of the tangent forces Ft were obtained for the grindingwheels (3T and 5T) during the grinding of titanium alloy TIGR5 with the useof polypropylene glycol (GP) with MQL. In case of the grinding wheel (3X); thetangent forces diered considerably from the remaining grinding wheels.The dierence in tangent force for polypropylene glycol and Biocut 3000 was66N. Similar results were achieved for the 3XG grinding wheel, namely 56N.The tangent force was considerably higher for titanium alloy (P), in comparisonto alloy (T), for all of the liquids used in the experiments. The smallest the forceswere noted when associating: the grinding wheel (3X) and grinding uid (BO).Use of polypropylene glycol eliminated the burning of the grinding surface, whichwas observed for other uids. This shows that applying polypropylene glycol withMQL during the grinding of titanium alloys is benecial.Grinding Process Results with Oil Mist 257Table 2 The grinding wheels, the grinding uids and the grindingSTOP GRINDING WHEELS PCS PPST, P 5TGP 54K VX (5T)3TGP 60K VX (3T)Propylene glycol(GP)Micro 3000 (MC)EcoCut micro 82 (EC)BioCut 3000 (BO)ae = 0:01  0:05[mm]vw = 0.2-0.5[m/s]T, P 3XGP 54K VX (3X) Propylene glycol(GP)Micro 3000 (MC)EcoCut micro 82 (EC)BioCut 3000 (BO)bD = 10[mm]vs = 22:5 26:5[m/s]050100150200250300CuttingforcesF t[N]5T 1 26 212 1 74 1923T 2 10 254 1 74 1823X 1 44 200 1 62 200GP MC EC BOFigure 1 The forces used by grinding wheels (5T, 3T, 3X) with the use of cutting uid with MQLfor alloy (T)0100200300CuttingforcesF t[N]5T 230 285 27 0 1643T 290 240 27 0 1643X 232 250 21 8 230GP MC EC BOFigure 2 The forces used by grinding wheels (5T, 3T, 3X) with the use of cutting uid with MQLfor alloy (P)258 Wojcik, R. and Wejman, P.The measurements of roughness were executed for plunge grinding with a singlepassage. Tab. 3 shows the extreme and middle (Raavg) values for parameter Ra,measured ve times.Table 3 Comparison of grinding wheels and cutting uids - lubricants and grinding processparametersGrinding uid Titanium alloys { grinding wheelTIGR5 { (5T) Ti-6Al-4V { (5T)Surface roughness [m]Ramin Ramax Raavg Ramin Ramax RaavgGP - Propyleneglycol0.44 0.49 0.47 0.49 0.66 0.58MC - Micro 3000 0.86 1.07 0.97 0.96 1.21 1.09BO - Biocut 3000 0.52 0.58 0.55 0.61 0.86 0.74EC - EcoCutmikro 820.90 1.01 0.96 0.66 0.86 0.76Grinding uid Titanium alloys { grinding wheelTIGR5 { (3T) Ti-6Al-4V { (3T)Surface roughness [m]Ramin Ramax Raavg Ramin Ramax RaavgGP - Propyleneglycol0.58 0.68 0.63 0.64 0.72 0.68MC - Micro 3000 1.26 1.34 1.30 1.26 1.75 1.51BO - Biocut 3000 0.84 1.37 1.11 0.68 0.92 0.80EC - EcoCutmikro 820.97 1.46 1.22 0.74 1.18 0.96Grinding uid Titanium alloys { grinding wheelTIGR5 { (3X) Ti-6Al-4V { (3X)Surface roughness [m]Ramin Ramax Raavg Ra nmi Ramax RaavgGP - Polypropy-lene glycol0.68 0.78 0.73 0.78 0.92 0.85MC - Micro 3000 1.26 1.68 1.47 0.70 1.30 1.00BO - Biocut 3000 0.84 1.37 1,11 1.31 1.44 1.38EC - EcoCutmikro 820.97 1.46 1.22 0.84 1.43 1.14The smallest average value, as well as, small changeability of the Ra parameterwas achieved during the grinding of the Tiger 5 alloy by grinding wheel 5T { 0.47m. The middle value Ra for another grinding wheel is: 0.63 m for 3T and 0.73m for 3X. Other grinding uids show: BO { 0.55 m, whereas for MC and ECthe Ra value is highest. In case of grinding the titanium alloy Ti-6Al-4V (P), themiddle Ra value was smallest for GP { 0.58 m.Grinding Process Results with Oil Mist 259)00 .40 .81 .21 .6Grinding f luidRaavg[um]T IGR5 – (5 T ) 0. 47 0. 97 0 .5 5 0 .9 6T i-6A l-4 V –(5 T )0. 58 1. 09 0 .7 4 0 .7 6GP MC BO E Cb)00.40.81.21.6Grinding fluidRaavg[um]TIGR5 – (3T) 0.63 1.3 1.11 1.22Ti-6Al-4V –(3T )0.68 1.51 0.8 0.96GP MC BO ECc)00.40.81.21.6Grinding fluidRaavg[um]T IGR5 – (3X) 0. 73 1 .4 7 0 1 .2 2T i-6 Al-4 V –(3 X)0. 85 1 1.38 1 .1 4GP MC BO ECFigure 3 Comparing the mean values for each parameter Ra wheels: a) 5TGP, b) 3TGP, c) 3XGP260 Wojcik, R. and Wejman, P.In Fig. 3 is a graph of the average value of the parameter Raavg examined casespresented and described in Tab. 3. They include such information as the type ofuid used to create mist and wheels that were tested in the order given in Tab. 3for the group of titanium alloys.The test pieces underwent deformation - inexion during the grinding. The stateof the test piece after plunge grinding. The opinion on deformations was based onthe following methodology. The test pieces were ground with a large stream ofgrinding uid to the depth ae = 0:005 mm only when they reached the temperatureof the surroundings.The initial state recorded was the moment of contact of the test piece and thegrinding wheel. The process was executed until the entire surface of the test piecewas reground. The deviation of atness between the initial and nal state of thetest piece was measured with an accuracy of 0.005 mm.The deformation of the test piece depends on the grinding uid and the materialof the grinding wheel { Fig. 4. The results are for grinding wheels TGP (3T and5T), 3XGP (3X) as well as studied of the grinding uid.The smallest deformation of the sample in one go at plunge grinding wheelsgrind obtained titanium alloy TIGR5 treatment liquid involving labeledGP -0.08 mm, (XG) -0.12 mm (EC) -0,13 mm, grinding wheel (3X). The largestshare of the treatment liquid MC -0.022 mm. For the grinding wheel (3X ) in theprocess of grinding GP -0.012 mm and the largest deformation at PCS denotedBO- 0.023 mm.00.0050.010.0150.020.0250.03Deformation[mm]5T 0.012 0.028 0 .022 0.0183T 0.014 0.021 0 .024 0.0133X 0.011 0.024 0 .019 0.011GP MC BO ECFigure 4 The inuence of the grinding uid and the material of the grinding wheel on thedeformation of the test piece3. ConclusionsResults show, that not for all studied titanium alloys, grinding wheels and grindinguids can the results show the desired state of the top layer and minimal deforma-tions. The eect of grinding depends on the chemical constitution of the titaniumalloy which inuences the temperatures of the structural transformation  ! .Grinding Process Results with Oil Mist 261The temperature of transformation 840-870oC for (P) and 990oC for (U) directlyinuences the physical and chemical properties of the alloy.Polypropylene glycol can be applied to the grinding of titanium alloys as grindinguid with a minimum expense of 50 ml/hour. This uid is cheap, easily accessibleand is not harmful for the operator, as well as, the environment.The consumption of glycol by the grinding of titanium alloys with MQL issmall. The lubricating properties contribute to the decrease of cutting forces, limitdeformation and damage of the top layer of thin objects.References[1] Burakowski, T. and Wierzchon, T.: In_zynieria powierzchni metali, WNT, 1995.[2] Bylica, A. and Sieniawski, J.: Tytan i jego stopy, PWN, 1985.[3] Karpinski, T. and Sieniawski, J.:Badania efektywnosci metody ch lodzenia stre-fowego w szlifowaniu p laszczyzn, Archiwum Technologii Maszyn i Automatyzacji, 21{29, 2005.[4] Kruszynski, B. and Wojcik, R.: Residual Stress in Grinding, Journal of MaterialsProcessing Technology, 2002.[5] Marciniak, J.: Biomateria ly w chirurgii kostnej, Wydawnictwo Politechniki Slaskiej,1992.[6] Oczos, K. E.: Doskonalenie strategii ch lodzenia i smarowania w procesachobrobkowych, Mechanik, 10, 597{649, 2004.[7] Oczos, K. E.: Rozwoj innowacyjnych technologii ubytkowego kszta ltowania mate-ria low. CZ II: Szlifowanie, Mechanik, 10, 2002.[8] Rosik, R.: Nowe zastosowanie glikolu propylenowego, P-390424, 2012.[9] Wojcik, R. and Rosik, R.: Badania wp lywu MQL z u_zyciem glikolu propylenowegona chropowatosc powierzchni przedmiotu szlifowanego, In_zynieria Maszyn, 15, 4, 122{131, 2010.[10] Wojcik, R.: Aktywny pomiar odkszta lcen i wyd lu_zen w procesie szlifowania, Archi-wum Technologii Maszyn i Automatyzacji, 29, 2, 74{78, 2009.[11] Wojcik, R: Nowe media i sposoby doprowadzenia do strefy szlifowania, ArchiwumTechnologii Maszyn i Automatyzacji, 28, 4, 137{145, 2008.[12] Wojcik, R. and Kruszynski, B.: Szlifowanie powierzchni p laskich z zastosowaniemminimalnego smarowania (minimum quantity lubrcation - mql), XXVII NaukowaSzko la Obrobki Sciernej, Krakow, 2003.[13] Wojcik, R.: Wp lyw gestosci strumienia energii szlifowania na napre_zenia w lasne wwarstwie wierzchniej, PhD thesis, No.7T O7D 018 09, 1997.[14] Wojcik, R.: The Eect of Grinding in Titanium Alloy Deformation, Mechanics andMechanical Eangineering, 17, 4, 5{15, 2013.

Grinding Process Results with Oil Mist.

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Grinding Process Results with Oil Mist.

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