Solid Lubricants in Ti-6Al-4V
BY –ANOOP KR. AGARWAL, AVNISH GAUR, ROHIT GOTHWAL
INTRODUCTION• Topic - Study of Solid Lubricants In Surface Grinding of
Titanium Alloys.
• Technique – Sandwich Grinding
• Alloy – Ti-6Al-4V
• Problem – Replace fluid coolants due to cost, air barrier, film boiling, etc.
• Approach – Reduce heat at its generation stage rather than removing the heat after its generation.
OBJECTIVES• Identify some Solid Lubricants, which can sustain and provide lubrication over a wider range of
temperatures.
• Development of three such wheels with varying number of slots for lubricant sandwiching.
• Study and analyze performance of these wheels and compare to conventional wheel in Dry Grinding.
• To study – Normal Force(Fn), Tangential Force(Ft), Grinding Force Ratio(Ft/Fn), Surface Roughness(Ra), and Intermittent work piece surface profiles and force pattern in continuous grinding test.
• Factors – Number of Slots, Type of Lubricant.
• Force measurements using a 3-component piezoelectric dynamometer.
• Surface roughness (Ra) of the ground part and its profiles using a Talysurf.
WORK PLAN & GANTT. CHARTTask % Done Sep. 01-07 Sep. 08-20 Sep. 20-25 Sep.26-
Oct. 15 Oct. 15- 31 Nov. 18 Nov. 815
Study research papers. -
Selection of Solid Lubricants
100
Design Grinding Wheel 100
Purchase 100
Develop sandwiched wheel.
100
Compare and analyse 0
Most efficient solution 0
Final observations 0
PROGRESS MADE
• First step was to study the process and decide the work plan. Gantt Chart was made accordingly and the stages were successfully executed.
• Choice of Sandwich Grinding technique for grinding process, among options like Taguchi method, Response Surface Method, etc.
• Criteria – Unexplored but the one which has potential and easily applicable.
• Deciding the process parameters & criteria for performing our experiments. Selection of Solid Lubricants.
EXPERIMENT PARAMETERS
• The idea was to create a design with required strength so that the wheel does not break but has enough clearance to provide appropriate lubrication.
• From those designs, we chose the ones which were practically feasible (could be cut) in the market.
• Final design was done considering specific geometry and tapering.
DESIGNING GRINDING WHEEL
PROGRESS MADE CUTTING THE WHEEL
• Most time consuming step in our project.
• Initial techniques considered were among Water Jet Machining, Diamond tool cutting, etc.
• Cutting was done using Diamond Cutter.
• Slots were cut at equal spacing, extending radially inward.
• More width was given to the slot at the inner side so that the taper formed at the slots converged towards the wheel periphery.
• The inner edge of the slots was given a radius.
Solid LubricantsGRAPHITE MOLYBDENU DISULPHIDE CALCIUM FLUORIDE
1 Fixed carbon: 80%-99.9% 2 Particle size:-300mesh 3 Moisture: 0.5%max
Size: 1.5um300 mesh flakesProperty: Pure grey powderParticle Size:-300mesh
Low SiO2 content.CaF2:98%, CaCO3:<1, Fe2O3:<0.03, Al2O3:<0.2, SiO2:<1, S:<0.02
SODIUM SULPHATE
Lubricant filler used with Graphite.
Development of Sandwiched Wheel
• After several trials, we concluded that lubricant filler, taken in a suitable composition, could be resin bonded with graphite in the slots.
• Composition by weight- 45% of fine graphite powder 55% of a mixture of sodium phosphate and sodium sulphate
in 30:70 by parts.
• The wheel is now ready for experimentation.
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