Abstract
To overcome environmental problems, nanofluid minimum quantity lubrication (NMQL) has been utilized as a burgeoning alternative technique to conventional flood machining, which consumes a large quantity of cutting fluid. Furthermore, spraying parameter optimization is a prerequisite of an effective NMQL grinding and a key to achieving a new sustainable grinding process. However, the spraying parameters of NMQL are multifarious and have varying degrees of influence on lubri-cooling performance. The main objective of this work is to first obtain good spraying parameters in NMQL grinding through the analysis of signal-to-noise ratio and analysis of variance based on orthogonal experiment results. Furthermore, an experimental verification is carried out on the basis of the relative optimization of several groups of spraying parameters from the orthogonal experiments. Power spectral density function (PSDF) and energy spectrum are used to analyze the workpiece and debris microtopography. Consequently, the optimal spraying parameter is obtained. The spraying parameter (palm oil as the base oil, 2 vol% nanoparticle concentration, 0.6 MPa air pressure, and 0.4 gas–liquid flow ratio) achieved the lowest proportionality coefficient (0.245) of PSDF in the low-frequency band and the highest (0.142) in the high-frequency band. Meanwhile, the optimal grinding performance is validated by the workpiece and debris microtopography and long-strip debris morphology.
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Funding
This research was financially supported by the National Natural Science Foundation of China (51575290 and 51806112), Major Research Project of Shandong Province (2017GGX30135 and 2018GGX103044), and Shandong Provincial Natural Science Foundation of China (ZR2017PEE002 and ZR2017PEE011).
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Xianpeng Zhang and Teng Gao are co-first authors.
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Zhang, X., Li, C., Jia, D. et al. Spraying parameter optimization and microtopography evaluation in nanofluid minimum quantity lubrication grinding. Int J Adv Manuf Technol 103, 2523–2539 (2019). https://doi.org/10.1007/s00170-019-03642-0
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DOI: https://doi.org/10.1007/s00170-019-03642-0