Application of ultrasonic vibration assisted MQL in grinding of Ti–6Al–4V

ABSTRACT

This work presents experimental investigations performed to evaluate the improvement in grinding performance of Ti–6Al–4V alloy using ultrasonic vibration assisted minimum quantity lubrication (UMQL) technique. The grinding experiments have been performed using an indigenously designed and fabricated UMQL setup. In UMQL, the ultrasonic vibration of the horn has been used to atomise the cutting fluid into ultra-fine droplets of uniform size. Sunflower oil in 1, 5 and 10% of the volume have been added in water to prepare the biodegradable emulsions and used as grinding medium. The grinding performance during UMQL has been evaluated by comparing the grinding forces, surface roughness and the ground surface topography obtained during dry and conventional MQL (CMQL) techniques. Surface quality and chip morphology have been studied using microscopic imaging techniques. The UMQL grinding results in smaller grinding forces, and improved surface quality as compared to CMQL grinding. The experimental findings demonstrate that the UMQL has a strong potential to enhance the grindability of Ti–6Al–4V. The present work is also a step forward in finding a sustainable grinding technique for high strength materials using vegetable oil as a coolant.

KEYWORDS:

• Biodegradable
• cooling
• droplet
• emulsion
• grinding
• lubrication
• MQL
• Ti–6Al–4V
• ultrasonic
• vibration

Acknowledgments

The authors are thankful to Mr. Subhash Chand, Technical Superintendent, Mechanical Engineering Department, IIT Delhi for his assistance during fabrication of the indigenously developed UMQL setup.