Evaluation of the grinding process utilizing an auxiliary compressed air jet on cleaning the grinding wheel surface

Grinding is one of the most complex and precise machining operations, with the performance of the grinding wheel being heavily reliant on its surface conditions. Removed chips tend to be forced back to the wheel surface due to the intense heat generated in the grinding zone. The loaded chips block the wheel's grinding capability, resulting in increased grinding force and temperature, wheel chatter, and workpiece thermal degradation. To solve these problems, this research examines the effectiveness of an auxiliary compressed air jet system during the grinding of spk tool steel with an alumina grinding wheel to clean the wheel surface of lodged chips and then the percentage of wheel loading for different tests will also be evaluated. The compressed air nozzle was examined from a variety of perspectives (0, 30, 45, and 60). Grinding with and without a cleaning system, as well as conventional cutting fluid, were also employed as comparisons. In certain output results, input parameters such as grinding wheel speed (20 m/s), cutting depth (20 m), and feed rate (100 mm/s) were maintained constant. When compared to other experiments with different cleaning nozzles, the optimal inclination angle of 45°, which allows the maximum air to reach the interface between the wheel surface and chips, removed chips by pushing them off the wheel surface. Other cleaning nozzles, such as 0°, 30°, and 60°, were less successful. The incidence angle of 45° produced the best results in terms of surface roughness, diametrical grinding wheel wear, G-ratio, tangential forces, specific energy, and wheel loading analysis. Image processing was used to detect and identify chips accumulated between abrasive grains on the wheel surface. To better understand the structure of the wheel and workpiece surface, optical and scanning electron microscopy pictures were taken and analyzed. This research adds to our understanding of the grinding wheel loading mechanism and its dynamics.