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An Experimental Study on Improving Grindability with LN2 Coolant for Grinding AISI D2 Tool Steel

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Abstract

In today’s modern manufacturing era, it is critical to have an environmentally friendly machining system. This research introduced a novel approach with a developed setup for applying liquid nitrogen (LN2) cryogen in cryogenic machining as an environmental concern. In order to facilitate meaningful comparisons, grinding experiments were carried out in three distinct environments: dry, wet, and cryogenic cooling. The experimental results revealed that compared to dry and wet cooling, cryogenic cooling is beneficial in lowering the grinding force (54-64% and 38-45% in Ft, 44-55% and 31-35% in Fn), reducing the temperature (64-69% and 50-56%), improving the surface finish, causing less damage to the surface condition, and forming C-type or semicircular chips. Also, the influences of different process parameters, which include table feed rate and cryogen pressure, on surface characteristics of AISI D2 tool steel while employing surface functional indices, namely, surface bearing index (Sbi) and core fluid retention index (Sci), were investigated. Outcomes showed that the Sbi and Sci values in cryogenic grinding were greater than those of dry and wet grinding under the same conditions. It was clearly observed that the results of Sbi and Sci under cryogenic cooling indicated better surface characteristics over the bearing characteristics and fluid retention properties of the ground sample.

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Acknowledgments

The authors are thankful for the funding support received from IIT (BHU) under the sprouting grant (letter no. IIT (BHU)/Dec/2013-14/5110/L) and Institute Research Project (IIT(BHU)/R&D)/IRP/2015-16/2832).

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  1. Department of Mechanical Engineering, Indian Institute of Technology BHU, Varanasi, 221005, India

    Ashwani Sharma, Abhimanyu Chaudhari, Mohd Zaheer Khan Yusufzai & Meghanshu Vashista

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Appendix

Appendix

The surface bearing index, Sbi, is defined to characterize the bearing characteristic of a surface. A surface with a higher Sbi offers superior bearing properties. The equation for calculating the Sbi:

$$Sbi = \frac{{S_{q} }}{{\eta_{0.05} }}$$
(1)

where Sq: root-mean-square (RMS) deviation; \(\eta_{0.05}\): surface height at 5% bearing area.

The core fluid retention index, Sci, is defined to characterize the property of fluid retention in the core zone. A greater Sci indicates that the surface can retain enough lubricants in the core zone, which is essential for better lubrication. The equation for calculating the Sci:

$$Sci = \frac{1}{{S_{q} }}\;\frac{{V_{v} \left( {h_{0.05} } \right) - V_{v} \left( {h_{0.08} } \right)}}{{\left( {M - 1} \right)\left( {N - 1} \right)\Delta x\Delta y}}$$
(2)

where \(V_{v} \left( {h_{0.05} } \right)\): void volume of the surface heights, \(h_{0.05}\); \(V_{v} \left( {h_{0.08} } \right)\): void volume of the surface heights, \(h_{0.08}\); M, and N indicate the number of sampling points in the \(x\) and \(y\) directions, and Δ\(x\) and Δ\(y\) are the sampling intervals.

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Sharma, A., Chaudhari, A., Yusufzai, M.Z.K. et al. An Experimental Study on Improving Grindability with LN2 Coolant for Grinding AISI D2 Tool Steel. J. of Materi Eng and Perform 33, 64–78 (2024). https://doi.org/10.1007/s11665-023-07958-7

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