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Performance of 3D-structured grinding wheels with multi-layer internal cooling channels

2025Journal article Open access
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datacite.subject.fosEngenharia e Tecnologia::Engenharia Mecânica
datacite.subject.fosEngenharia e Tecnologia::Engenharia dos Materiais
datacite.subject.fosEngenharia e Tecnologia::Outras Engenharias e Tecnologias
datacite.subject.sdg09:Indústria, Inovação e Infraestruturas
datacite.subject.sdg12:Produção e Consumo Sustentáveis
dc.contributor.authorCosta, Sharlane
dc.contributor.authorCapela, Paulina
dc.contributor.authorHassui, Amauri
dc.contributor.authorRibeiro, J.E.
dc.contributor.authorPereira, Mário
dc.contributor.authorSoares, Delfim
dc.date.accessioned2025-12-05T16:16:56Z
dc.date.available2025-12-05T16:16:56Z
dc.date.issued2025
dc.description.abstractGrinding is a key machining process in industries that demand high precision and surface quality. However, the conventional flood cooling method is often ineffective due to the air barrier formed by the rotating wheel, which restricts fluid access to the contact zone. This causes thermal instability, high coolant use, and environmental impact. To overcome these limitations, this study investigates alumina grinding wheels with internal cooling systems, fabricated by a novel additive route. Sacrificial 3D-printed polymer inserts were embedded during pressing and eliminated during sintering, enabling multilayered channels within a monolithic abrasive matrix. This represents the first practical application, with detailed method of production, of a fully embedded cooling system in vitrified grinding wheels. Two configurations, with one and three internal channel layers, were compared to a conventional wheel under external cooling. Controlled grinding tests on AISI 1045 steel were performed at varying depths of cut, and key variables such as cutting forces, force ratio, specific energy, and temperature variation (Delta T) were analyzed. The three-layer wheel showed the best performance, reducing tangential force by up to 49.3 %, force ratio by 21.3 %, specific energy by 50 %, and Delta T by 58.6 % compared to the conventional system. A detailed thermal profile enabled segmentation into cut-in, steady-state, and cut-out zones. The greatest benefit from internal cooling occurred in the steady-state region, with heating rates reduced by up to 78 %. These results confirm that the proposed additive manufacturing approach offers a scalable route to produce structured wheels with embedded channels, improving coolant application, process stability, and sustainability in high-performance grinding.eng
dc.description.sponsorshipThis work was supported by FCT national funds, under the national support to R&D units grant, through the reference project UIDB/04436. The authors are grateful to the Foundation for Science and Technology (FCT, Portugal) for financial support through national funds FCT/MCTES (PIDDAC) to CIMO (UIDB/00690/2020 and UIDP/00690/2020) and SusTEC (LA/P/0007/2020). 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 Ph.D grant reference 2021.07352.BD (DOI:https://doi.org/10.54499/2021.07352.BD). Paulina Capela acknowledges the financial support from FCT through the doctoral grant 2024.01273.BDANA.
dc.identifier.citationCosta, Sharlane; Capela, Paulina; Hassui, Amauri; Ribeiro, João E.; Pereira, Mario; Soares, Delfim. (2025). Performance of 3D-structured grinding wheels with multi-layer internal cooling channels. Results in Engineering. ISSN 2590-1230. 28, p. 1-12
dc.identifier.doi10.1016/j.rineng.2025.107881
dc.identifier.issn2590-1230
dc.identifier.urihttp://hdl.handle.net/10198/35193
dc.language.isoeng
dc.peerreviewedyes
dc.publisherElsevier
dc.relationMicroelectromechanical Systems Research Unit
dc.relationMountain Research Center
dc.relationAssociate Laboratory for Sustainability and Tecnology in Mountain Regions
dc.relation.ispartofResults in Engineering
dc.rights.urihttp://creativecommons.org/licenses/by-nc/4.0/
dc.subjectStructured grinding wheel
dc.subjectGrinding temperature
dc.subjectTribological performance
dc.subjectSustainable manufacturing
dc.subjectHigh-efficiency grinding
dc.subjectInternal cooling channels
dc.titlePerformance of 3D-structured grinding wheels with multi-layer internal cooling channelseng
dc.typejournal article
dspace.entity.typePublication
oaire.awardTitleMicroelectromechanical Systems Research Unit
oaire.awardTitleMountain Research Center
oaire.awardTitleAssociate Laboratory for Sustainability and Tecnology in Mountain Regions
oaire.awardURIinfo:eu-repo/grantAgreement/FCT/6817 - DCRRNI ID/UIDB%2F04436%2F2020/PT
oaire.awardURIinfo:eu-repo/grantAgreement/FCT/6817 - DCRRNI ID/UIDP%2F00690%2F2020/PT
oaire.awardURIinfo:eu-repo/grantAgreement/FCT/6817 - DCRRNI ID/LA%2FP%2F0007%2F2020/PT
oaire.citation.endPage12
oaire.citation.startPage1
oaire.citation.titleResults in Engineering
oaire.citation.volume28
oaire.fundingStream6817 - DCRRNI ID
oaire.fundingStream6817 - DCRRNI ID
oaire.fundingStream6817 - DCRRNI ID
oaire.versionhttp://purl.org/coar/version/c_970fb48d4fbd8a85
person.familyNameCosta
person.familyNameRibeiro
person.givenNameSharlane
person.givenNameJ.E.
person.identifierR-000-6Y8
person.identifier.ciencia-idBE10-34C7-7A2D
person.identifier.ciencia-id0F15-FB62-29DB
person.identifier.orcid0000-0001-6300-148X
person.identifier.ridG-3839-2018
person.identifier.scopus-author-id25638652400
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
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