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Metals
Special Issues
Study of Grinding Processes for Metals and Alloys
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Special Issue "Study of Grinding Processes for Metals and Alloys"

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Structural Integrity of Metals".

Deadline for manuscript submissions: closed (28 February 2023) | Viewed by 3719

Special Issue Editor

Prof. Dr. Rosemar Batista da Silva

E-Mail Website
Guest Editor
School of Mechanical Engineering, Federal University of Uberlândia, Av. João Naves de Ávila, 2121, Uberlândia 38408-144, MG, Brazil
Interests: grinding; cutting fluids; solid lubricants; grinding of superalloys; surface integrity; thermal damages; cutting power; sustainability

Special Issue Information

Dear Colleagues,

The grinding process dates from the prehistoric man, where it was employed to provide a desired shape and sharpen his tools, as well as to produce artifacts by rubbing them on a slab of gritty rocks, such as sandstone. Since then, the importance of grinding has increased significantly, and humanity has become more dependent on grinding because many components from several industries, such as metal working, cutlery, electrical, microelectronic, automotive, aerospace, oil, and railway, among others, have some requirements that could be achieved by grinding as a first option. In other words, grinding aims to achieve a combination of tight dimensional tolerances and low surface roughness (Ra parameters) to uncountable type of parts. However, grinding is a peculiar process when compared to machining with single edge tools. Cutting is performed by the action of thousands of hard abrasive particles with undefined geometry and randomly distributed throughout the wheel volume. Additionally, grinding wheels work at a high cutting speed, and the radial depth of the cut is generally on a micrometric scale. The presence of cutting fluid is quite indispensable in grinding because of the great amount of heat that is generated in the grinding zone as a result of numerous grit edges in contact with the workpiece.

Compensating for the increase in the material removal rate with low temperatures in the grinding zone, in order to reduce the portion of heat that is transferred to the workpiece during grinding and avoid the occurrence of thermal damage to the workpiece, is perhaps the biggest challenge today. 

All these peculiarities make grinding even more attractive for researchers and machining users from many industries, thereby representing opportunities for new research topics.

This Special Issue aims to address the latest research in grinding metals and alloys, which can really bring contributions to academics, engineers, and machining professionals from various industries.

Prof. Dr. Rosemar Batista da Silva
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2000 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • grinding
  • abrasion process
  • hardened steels
  • superalloys
  • grinding temperature
  • grinding forces
  • thermal damages
  • grinding wheel
  • cutting fluid
  • resharpening
  • solid lubricants in grinding
  • minimum quantity lubrication
  • cutting parameters
  • dimensional errors
  • geometric tolerances
  • surface integrity
  • seeded gel
  • alumina oxide
  • silicon carbide
  • productivity
  • economics of grinding

Published Papers (3 papers)

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Article
Reduced Friction and Excellent Anti-Wear Performance of QBe2 Beryllium Bronze against 38CrMoAlA Steel in Pneumatic Downhole Motor under Grease Lubrication
by
Chenfan Liang
,
Jing Zhou
,
Yu Wang
and
Zhijian Peng
Metals 2023, 13(2), 266; https://doi.org/10.3390/met13020266 - 29 Jan 2023
Viewed by 483
Abstract
To improve the service life of the newly designed pneumatic downhole motor, a kind of commercially available lithium complex grease was used to help avoid the rapid wear-induced failure of the dynamic seal of pneumatic downhole tools in operation. The investigation on the [...] Read more.
To improve the service life of the newly designed pneumatic downhole motor, a kind of commercially available lithium complex grease was used to help avoid the rapid wear-induced failure of the dynamic seal of pneumatic downhole tools in operation. The investigation on the tribological behaviors of QBe2 beryllium bronze and 38CrMoAlA steel tribo-pairs in pneumatic downhole motor revealed that under lubrication, the instantaneous friction coefficient and wear volume became very low, showing greatly reduced friction and excellent anti-wear performance. Compared with the case without lubrication, the adhesive wear mechanism and ploughing effect of the tribo-pairs were significantly alleviated. Moreover, Cu and Fe were oxidized to form composite oxides between the frictional surface, further improving the lubrication effect between the QBe2 beryllium bronze and 38CrMoAlA steel. Notably, the test could be operated stably for more than 150 h under lubrication, fully reaching the requirement of pneumatic downhole tools under actual drilling conditions. These results provide a solid support for the practical application of the reported pneumatic downhole tools. Full article
(This article belongs to the Special Issue Study of Grinding Processes for Metals and Alloys)
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Article
Improvement of Shape Error for Slender Parts in Cylindrical Traverse Grinding by Part-Deformation Modelling and Compensation
by
Ivan Mendez
,
Jorge Alvarez
,
David Barrenetxea
and
Leire Godino
Metals 2021, 11(12), 1990; https://doi.org/10.3390/met11121990 - 09 Dec 2021
Viewed by 1365
Abstract
Achieving geometrical accuracy in cylindrical traverse grinding for high-aspect slender parts is still a challenge due to the flexibility of the workpiece and, therefore, the resulting shape error. This causes a bottleneck in production due to the number of spark-out strokes that must [...] Read more.
Achieving geometrical accuracy in cylindrical traverse grinding for high-aspect slender parts is still a challenge due to the flexibility of the workpiece and, therefore, the resulting shape error. This causes a bottleneck in production due to the number of spark-out strokes that must be programmed to achieve the expected dimensional and geometrical tolerances. This study presents an experimental validation of a shape-error prediction model in which a distributed load, corresponding to the grinding wheel width, is included, and allows inclusion of the effect of steady rests. Headstock and tailstock stiffness must be considered and a procedure to obtain their values is presented. Validation of the model was performed both theoretically (by comparing with FEM results) and experimentally (by comparing with the deformation profile of the real workpiece shape), obtaining differences below 5%. Having determined the shape error by monitoring the normal grinding force, a solution was presented to correct it, based on a cross-motion of the grinding wheel during traverse strokes, thus decreasing non-productive spark-out strokes. Due to its simplicity (based on the shape-error prediction model and normal grinding force monitoring), this was easily automatable. The corrective compensation cycle gave promising results with a decrease of 77% in the shape error of the ground part, and improvement in geometrically measured parameters, such as cylindricity and straightness. Full article
(This article belongs to the Special Issue Study of Grinding Processes for Metals and Alloys)
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Article
An Approach to Reduce Thermal Damages on Grinding of Bearing Steel by Controlling Cutting Fluid Temperature
by
Raphael Lima de Paiva
,
Rodrigo de Souza Ruzzi
and
Rosemar Batista da Silva
Metals 2021, 11(10), 1660; https://doi.org/10.3390/met11101660 - 19 Oct 2021
Cited by 1 | Viewed by 1206
Abstract
The use of cutting fluid is crucial in the grinding process due to the elevated heat generated during the process which typically flows to the workpiece and can adversely affect its integrity. Considering the conventional technique for cutting fluid application in grinding (flood), [...] Read more.
The use of cutting fluid is crucial in the grinding process due to the elevated heat generated during the process which typically flows to the workpiece and can adversely affect its integrity. Considering the conventional technique for cutting fluid application in grinding (flood), its efficiency is related to certain factors such as the type of fluid, nozzle geometry/positioning, flow rate and coolant concentration. Another parameter, one which is usually neglected, is the cutting fluid temperature. Since the heat exchange between the cutting fluid and workpiece increases with the temperature difference, controlling the cutting fluid temperature before its application could improve its cooling capability. In this context, this work aimed to analyze the surface integrity of bearing steel (hardened SAE 52100 steel) after grinding with an Al2O3 grinding wheel with the cutting fluid delivered via flood technique at different temperatures: 5 °C, 10 °C, 15 °C as well as room temperature (28 ± 1 °C). The surface integrity of the workpiece was analyzed in terms of surface roughness (Ra parameter), images of the ground surface, and the microhardness and microstructure beneath the machined surface. The results show that the surface roughness values reduced with the cutting fluid temperature. Furthermore, the application of a cutting fluid at low temperatures enabled the minimization of thermal damages regarding visible grinding burns, hardness variation, and microstructure changes. Full article
(This article belongs to the Special Issue Study of Grinding Processes for Metals and Alloys)
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