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A New Grinding Wheel Design with a 3D Internal Cooling Structure System

2024Journal article Open access
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dc.contributor.authorCosta, Sharlane
dc.contributor.authorCapela, Paulina
dc.contributor.authorSouza, Maria S.
dc.contributor.authorGomes, José R.
dc.contributor.authorCarvalho, Luís
dc.contributor.authorPereira, Mário J.
dc.contributor.authorSoares, Delfim
dc.date.accessioned2024-10-16T08:50:57Z
dc.date.available2024-10-16T08:50:57Z
dc.date.issued2024
dc.description.abstractThis work discusses challenges in conventional grinding wheels: heat-induced tool wear and workpiece thermal damage. While textured abrasive wheels improve heat dissipation, the current surface-only methods, such as those based on laser and machining, have high renewal costs. The proposed manufacturing technology introduces an innovative 3D cooling channel structure throughout the wheel, enabling various channel geometries for specific abrasive wheel applications. The production steps were designed to accommodate the conventional pressing and sintering phases. During pressing, a 3D organic structure was included in the green body. A drying cycle eliminated all present fluids, and a sintering one burnt away the structure, revealing channels in the final product. Key parameters, such as binder type/content and heating rate, were optimized for reproducibility and scalability. Wear tests showed a huge efficiency increase (>100%) in performance and durability compared of this system to conventional wheels. Hexagonal channel structures decreased the wear rates by 64%, displaying superior wear resistance. Comprehensive CFD simulations evaluated the coolant flow through the cooling channels. This new design methodology for three-dimensionally structured grinding wheels innovates the operation configuration by delivering the coolant directly where it is needed. It allows for increasing the overall efficiency by optimizing cooling, reducing tool wear, and enhancing manufacturing precision. This 3D channel structure eliminates the need for reconditioning, thus lowering the operation costs.pt_PT
dc.description.sponsorshipThis work was supported by FCT national funds, under the national support to R&D units grant, through the reference projects UIDB/04436/2020 and UIDP/04436/2020. This work is within the scope of Sharlane Costa Ph.D. degree, in progress, financially supported by the Portuguese Foundation for Science and Technology (FCT) through the PhD grant reference 2021.07352.BD.pt_PT
dc.description.versioninfo:eu-repo/semantics/publishedVersionpt_PT
dc.identifier.citationCosta, Sharlane; Capela, Paulina; Souza, Maria S.; Gomes, José R.; Carvalho, Luís; Pereira, Mário; Soares, Delfim (2024). A New Grinding Wheel Design with a 3D Internal Cooling Structure System. Journal of Manufacturing and Materials Processing. ISSN 2504-4494. 8:4, p. 1-20pt_PT
dc.identifier.doi10.3390/jmmp8040159pt_PT
dc.identifier.issn2504-4494
dc.identifier.urihttp://hdl.handle.net/10198/30427
dc.language.isoengpt_PT
dc.peerreviewedyespt_PT
dc.publisherMDPIpt_PT
dc.relationMicroelectromechanical Systems Research Unit
dc.relationMicroelectromechanical Systems Research Unit
dc.rights.urihttp://creativecommons.org/licenses/by/4.0/pt_PT
dc.subjectStructured grinding wheelpt_PT
dc.subject3D cooling channelspt_PT
dc.subjectAdditive manufacturingpt_PT
dc.subjectWear resistancept_PT
dc.subjectCooling efficiencypt_PT
dc.subjectPrecision manufacturing advancementspt_PT
dc.titleA New Grinding Wheel Design with a 3D Internal Cooling Structure Systempt_PT
dc.typejournal article
dspace.entity.typePublication
oaire.awardTitleMicroelectromechanical Systems Research Unit
oaire.awardTitleMicroelectromechanical Systems Research Unit
oaire.awardURIinfo:eu-repo/grantAgreement/FCT/6817 - DCRRNI ID/UIDB%2F04436%2F2020/PT
oaire.awardURIinfo:eu-repo/grantAgreement/FCT/6817 - DCRRNI ID/UIDP%2F04436%2F2020/PT
oaire.awardURIinfo:eu-repo/grantAgreement/FCT/POR_NORTE/2021.07352.BD/PT
oaire.citation.endPage20pt_PT
oaire.citation.issue4pt_PT
oaire.citation.startPage1pt_PT
oaire.citation.titleJournal of Manufacturing and Materials Processingpt_PT
oaire.citation.volume8pt_PT
oaire.fundingStream6817 - DCRRNI ID
oaire.fundingStream6817 - DCRRNI ID
oaire.fundingStreamPOR_NORTE
person.familyNameCosta
person.givenNameSharlane
person.identifier.ciencia-idBE10-34C7-7A2D
project.funder.identifierhttp://doi.org/10.13039/501100001871
project.funder.identifierhttp://doi.org/10.13039/501100001871
project.funder.identifierhttp://doi.org/10.13039/501100001871
project.funder.nameFundação para a Ciência e a Tecnologia
project.funder.nameFundação para a Ciência e a Tecnologia
project.funder.nameFundação para a Ciência e a Tecnologia
rcaap.rightsopenAccesspt_PT
rcaap.typearticlept_PT
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relation.isAuthorOfPublication.latestForDiscovery0ec5f1a9-0ab7-4001-8b6d-11b51dc78fa7
relation.isProjectOfPublication9958a65b-455f-4f87-a58f-0d7bcf0934e9
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