1. Solid Lubricants in Ti-6Al4V
BY –ANOOP KR. AGARWAL, AVNISH GAUR, ROHIT
GOTHWAL
2. 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.
3. 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.
4. WORK PLAN & GANTT. CHART
Task
% Done
Sep. 01-07
Sep. 08-20
Sep. 20-25
Sep.26Oct. 15
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
Oct. 15- 31
Nov. 18
Nov. 815
5. PROGRESS
MADE
EXPERIMENT
PARAMETERS and decide the work
• First step was to study the process
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.
6. DESIGNING GRINDING WHEEL
•
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.
7. 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.
9. 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.
