Although the function of the grinding grinding fluid is primarily to cool the process, it also has to cool the grinding wheel (very important with resin-bonded diamond wheels), allow the lubricants in the grinding fluid to do their job (especially important with both conventional & superabrasive wheels), flush the chips from the machine and workpiece area, and clean the wheel, especially when grinding ductile materials using water-based grinding fluid.
The method of applying fluid into a grinding process is a highly neglected area and if correctly done can have a significant influence on the surface finish, surface integrity and productivity achieved. The following benefits can often be realized with superabrasive grinding wheels, by improved grinding fluid application:
- Reduced dressing frequency, due to less loading with work material, and more effective use of the EP additives into the process
- A harder grade of grinding wheel can be used, improving form holding and reducing dressing frequency
- Thermal damage of the workpiece material is reduced, allowing higher removal rates and greater throughput
- More of the applied flowrate will be effective, such that the overall applied flowrate may even be reduced and filter capacity downsized
- Reduced applied flowrate can also reduce the pumping and chilling energy costs
- Reduction in entrained air (foaming), misting and vapor problems.
- Reduced disturbance of the jet from the air barrier surrounding the wheel
- Robust set-up is possible using round and rectangular nozzles for profiled wheels
- Increased material removal rates can be explored
- No need to reduce wheelspeed to alleviate burn