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Bijoy Mandal ¹, Debashis Biswas ¹, Anirban Sarkar ¹, Santanu Das ¹, Simul Banerjee ²

Affiliations
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani-741235, IN
2 Department of Mechanical Engineering, Jadavpur University, Kolkata-700032, IN

Abstract

Grinding fluid application is important to control thermal related problems while grinding titanium alloys. Conventional fluid delivery systems are not able to deliver grinding fluid deep into the grinding zone because of the presence of a stiff air layer around a rotating grinding wheel. A newly developed pneumatic barrier system is used in this experimental investigation to penetrate the air layer so as to deliver fluid into grinding zone. Dry, flood cooling and flood cooling with pneumatic barrier conditions are used to explore the influence of these environmental conditions on grindability of titanium grade 1 workpiece. It is seen that under flood cooling using pneumatic barrier, better grinding performance is obtained than conventional flood cooling condition.

Keywords

Grinding, Pneumatic Barrier, Grinding Fluid, Titanium Alloy, Air Layer.

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Debashis Biswas ¹, Anirban Sarkar ¹, Bijoy Mandal ¹, Santanu Das ¹

Affiliations
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani-741235, IN

Abstract

Titanium and its alloys are being increasingly used in aerospace engineering, corrosive fluid pumps, heat exchangers, sea vehicles, etc. However, it is quite difficult to grind for its high chemical reactivity, high strength, high hardenability and low thermal conductivity causing high grinding temperature, wheel loading, wheel material removal, grit wear, etc. Therefore, selection of wheel, wheel speed and fluid for grinding of titanium is important to achieve desirable surface quality. Formation of a stiff air layer is a major constrain restricting the fluid enter the grinding zone. Optimization of a method of grinding fluid application is essential to control thermal problems from interaction of the wheel grains with the work surface. Adopting an appropriate fluid delivery system may enhance grindability of titanium alloy and can reduce environmental pollution. In the present experimental work, surface roughness, grinding forces and grinding chips are observed under the condition of dry, and wet using a compound nozzle. Surface grinding of titanium Grade 1 alloy is done with the use of silicon carbide wheel. It is found out that grinding under wet with compound nozzle fluid delivery system exhibits fairly good grindability.

Keywords

Surface Grinding, Compound Nozzle, Titanium Alloy, Silicon Carbide Wheel.

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Bijoy Mandal ¹, Debashis Biswas ², Anirban Sarkar ², Santanu Das ²

Affiliations
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani, IN
2 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani - 741 235, IN

Abstract

Study of chips favours judging the performance of machining and grinding Different kinds of chip formation are related to specific energy consumptions, heat produce, etc. The nature of the chip forming process is extremely vanable and depends upon the metallurgical aspect of the tool-work pair, un-deformed chip thickness, rake angle, cutting temperature, sharpness of the tool, etc Observation of chip formation during grinding of a specific matenal may facilitate determine the appropriate wheel speed, table feed and infeed for efficient grinding in this experimental study, grinding chips under different infeeds and environmental conditions have been investigated for low carbon steel specimens Good grinding performance has been achieved when water-soluble oil is used as a grinding fluid with pneumatic barrier set up.

Keywords

Grinding Chips, Surface Grinding, Surface Quality, Pneumatic Barner.

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Bijoy Mandal ¹, Anirban Sarkar ¹, Debashis Biswas ¹, Santanu Das ¹, Simul Banerjee ²

Affiliations
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani-741235, IN
2 Department of Mechanical Engineering, Jadavpur University, Kolkata- 700 032, IN

Abstract

Conventional fluid delivery system is not much effective to reduce heat generation due to presence of a stiff air layer covering the periphery of grinding wheel. Thermal damages in grinding a super alloy are stringent and problematic. In this paper, a report on the experimental investigation carried out on grinding a nickel based super alloy, Inconnel-600 is made. Different infeeds are considered with dry, wet and wet with pneumatic barrier conditions. To break the stiff air layer covering grinding wheel, high pressure air jet is employed just above the conventional grinding fluid nozzle to facilitate grinding fluid reach the wheel-workpiece interface area. This is termed as a pneumatic barrier. Grinding performance under these environmental conditions has been investigated. Results show better grinding performance with the application of pneumatic barrier in the wet condition as it tends to facilitate fluid reach deep inside the grinding zone effectively.

Keywords

Surface Grinding, Grinding Fluid, Air Layer, Pneumatic Barrier; Grinding Chip, Surface Roughness, Grinding Forces, Flood Cooling Nozzle, Pneumatic Barrier Nozzle, Inconnel-600.

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Bijoy Mandal ¹, Debashis Biswas ¹, Anirban Sarkar ¹, Santanu Das ¹, Simul Banerjee ²

Affiliations
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani-741235, IN
2 Department of Mechanical Engineering, Jadavpur University, Kolkata-700032, IN

Abstract

High grinding zone temperature often results in several grinding defects. For controlling this, usually large amount of grinding fluid is applied. However, synthetic grinding fluid or cutting fluid has some adverse impact on environment, and, hence, researchers are trying to reduce the application of grinding fluid. In this experimental investigation, a specially developed compound nozzle is used for delivering grinding fluid. Fluid may reach easily into grinding zone at low discharge by using this nozzle. Discharge of the nozzle is about 52% less than conventional flood cooling. Grinding results obtained under different environment are compared. It is found that better grinding performance is obtained by using this compound nozzle than conventional flood cooling grinding; as consumption of grinding fluid is substantially reduced, use of compound nozzle may be more economical and advantageous to control industrial pollution.

Keywords

Surface Grinding, Compound Nozzle, Grinding Fluid, Surface Roughness, Flood Cooling.

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