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首页> 外文期刊>Journal of Manufacturing Processes >An investigation on application of nano-fluids in high speed grinding of sintered alumina
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An investigation on application of nano-fluids in high speed grinding of sintered alumina

机译：纳米流体在烧结氧化铝高速磨削中的应用研究

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摘要

Ceramics are the most sought-after materials in various advanced engineering applications. Diamond abrasive machining is used to achieve dimensional tolerances for hard ceramic materials. Micro-brittle fracture and grain dislodgement are the primary material removal mechanisms which generate surface and sub-surface defects. High processing cost and manufacturing defects limit their widespread use. This paper investigates the effectiveness of different grinding environments in reducing the brittle fracture in high speed grinding of highly pure and dense alumina work samples using single layer electroplated diamond grinding wheel. Grinding environments included straight cutting oil, water soluble oil at 5% concentration (soluble oil), and two water based nanofluids of alumina and hBN, all in Minimum Quantity Lubrication (MQL) mode. Conventional flood cooling with 5% concentration of soluble oil in water was used as the benchmark. Grinding forces were measured to estimate the specific grinding energy and apparent coefficient of friction. Surface integrity aspects of ground samples such as surface morphology, surface roughness and residual stresses were studied using Scanning Electron Microscope (SEM), 3D surface profilometer and x-ray diffractometer, respectively. Morphology of the grinding wheel was studied using stereo zoom microscope. Based on the experimental observations, a new model is proposed to demonstrate the interaction of nanoparticles in the grinding zone for grinding of brittle materials including alumina. Results showed that the nanofluid MQL yielded highly fractured surface because of high contact stress fields, whereas straight cutting oil MQL provided better lubrication in the grinding zone which promoted ductile deformation. Compressive residual stresses of the order of 105 MPa were observed in the samples ground with straight cutting oil MQL which can improve the fatigue life. Single scratch experiments done using diamond indenter also showed better lubrication efficiency of the straight cutting oil in comparison with soluble oil.
机译：陶瓷是各种高级工程应用中最抢手的材料。金刚石磨料加工用于获得硬质陶瓷材料的尺寸公差。微脆性断裂和晶粒脱落是产生表面和亚表面缺陷的主要材料去除机制。高处理成本和制造缺陷限制了它们的广泛使用。本文研究了在使用单层电镀金刚石砂轮高速研磨高纯度和高密度氧化铝工件时，不同研磨环境在减少脆性断裂方面的有效性。研磨环境包括直切削油，浓度为5％的水溶性油（可溶性油）以及氧化铝和hBN的两种水基纳米流体，均以最小量润滑（MQL）模式运行。以水中溶解油浓度为5％的常规洪水冷却为基准。测量磨削力以估计比磨削能和表观摩擦系数。分别使用扫描电子显微镜（SEM），3D表面轮廓仪和X射线衍射仪研究了地面样品的表面完整性，例如表面形态，表面粗糙度和残余应力。使用立体变焦显微镜研究了砂轮的形态。基于实验观察结果，提出了一种新的模型来演示纳米颗粒在研磨区中的相互作用，以研磨包括氧化铝在内的脆性材料。结果表明，由于高接触应力场，纳米流体MQL产生了高度断裂的表面，而直切削油MQL在磨削区提供了更好的润滑，从而促进了塑性变形。在使用直切削油MQL研磨的样品中观察到约105 MPa的压缩残余应力，这可以改善疲劳寿命。使用金刚石压头进行的单划痕实验还显示，与可溶性油相比，直切削油的润滑效率更高。

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