Comparative assessment of force, temperature, and wheel wear in sustainable grinding aerospace alloy using biolubricant

Abstract

The substitution of biolubricant for mineral cutting fluids in aerospace material grinding is an inevitable development direction, under the requirements of the worldwide carbon emission strategy. However, serious tool wear and workpiece damage in difficult-to-machine material grinding challenges the availability of using biolubricants via minimum quantity lubrication. The primary cause for this condition is the unknown and complex influencing mechanisms of the biolubricant physicochemical properties on grindability. In this review, a comparative assessment of grindability is performed using titanium alloy, nickel-based alloy, and high-strength steel. Firstly, this work considers the physicochemical properties as the main factors, and the antifriction and heat dissipation behaviours of biolubricant in a high temperature and pressure interface are comprehensively analysed. Secondly, the comparative assessment of force, temperature, wheel wear and workpiece surface for titanium alloy, nickel-based alloy, and high-strength steel confirms that biolubricant is a potential replacement of traditional cutting fluids because of its improved lubrication and cooling performance. High-viscosity biolubricant and nano-enhancers with high thermal conductivity are recommended for titanium alloy to solve the burn puzzle of the workpiece. Biolubricant with high viscosity and high fatty acid saturation characteristics should be used to overcome the bottleneck of wheel wear and nickel-based alloy surface burn. The nano-enhancers with high hardness and spherical characteristics are better choices. Furthermore, a different option is available for high-strength steel grinding, which needs low-viscosity biolubricant to address the debris breaking difficulty and wheel clogging. Finally, the current challenges and potential methods are proposed to promote the application of biolubricant.

Graphical abstract

Keywords

grinding / aerospace / difficult-to-machine material / biolubricant / physicochemical property / grindability

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Nomenclature

Abbreviations
CBN	Cubic boron nitride
CNT	Carbon nano tube
CoF	Coefficient of friction
CWCJ	Cooled wheel cleaning jet
EDS	Energy dispersive spectrometry
MQL	Minimum quantity lubrication
MWCNT	Multi-walled carbon nano tube
NMQL	Nanolubricant minimum quantity lubrication
SEM	Scanning electron microscopy
WCJ	Wheel cleaning jet
Variables
ap	Grinding depth
Fn	Normal grinding force
Ft	Tangential grinding force
qd	Heat flux density of debris
qc	Heat flux density of the cooling medium
qa	Heat flux density of abrasive
qw	Heat flux density of the workpiece
Qtotal	Total heat flux density
Ra	Surface roughness
Vs	Peripheral speed of grinding wheel
Vw	Workpiece feed speed
Λw	Material removal rate

Acknowledgements

This research was financially supported by the National Natural Science Foundation of China (Grant Nos. 52105457 and 51975305), the National Key R&D Program of China (Grant No. 2020YFB2010500), the Shandong Natural Science Foundation, China (Grant Nos. ZR2020KE027 and ZR2020ME158), the Innovation Talent Supporting Program for Postdoctoral Fellows of Shandong Province, China (Grant No. SDBX2020012), and the Major Science and Technology Innovation Engineering Projects of Shandong Province, China (Grant No. 2019JZZY020111).

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