Industrial Lubrication and Tribology

Emerald Article: A performance simulator for grinding coolant evaluation

T.D. Lavanya, V.E. Annamalai

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To cite this document:
T.D. Lavanya, V.E. Annamalai, (2012),"A performance simulator for grinding coolant evaluation", Industrial Lubrication and
Tribology, Vol. 64 Iss: 4 pp. 224 - 229
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http://dx.doi.org/10.1108/00368791211232771
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 A performance simulator for grinding coolant
evaluation
T.D. Lavanya
Research & Development, SAK Abrasives, Chennai, India, and
V.E. Annamalai
Mechanical Engineering, SSN College of Engineering, Chennai, India

Abstract
Purpose – The purpose of this paper is to simplify the testing of coolants for grinding in the automotive industry.
Design/methodology/approach – A simple equipment is developed to test the coolant, by simulating the coolant-grinding wheel-workpiece
interface and measuring in terms of grinding parameters.
Findings – It was found that the simulator could indicate the performance trends that closely match the actual grinding conditions.
Research limitations/implications – Since this is a general system, it has to be customised with individual settings of the machining parameters for a
meaningful interpretation and for comparison between machines.
Practical implications – This equipment will simplify the selection of coolants for grinding and serve as a pre-qualifier before approving for trials in
full-scale shopfloor conditions.
Originality/value – The design of the equipment is new and provides an alternate for the otherwise costly, full-scale evaluation of coolants on the
shopfloor.

Keywords Automotive industry, Grinding, Abrasives, Cooling, Dressing, Coolant, Wear test, Simulation, Grinding performance

Paper type Research paper

1. Introduction
Grinding is an important metal finishing operation for most of
the automotive components (Vedhavalli and Annamalai,
2007). There is a constant urge to improve the process of
grinding for many reasons like better surface finish or
improved productivity. Improved productivity is normally
associated with increased grinding wheel speeds. Grinding
wheels can be produced to meet these high speed needs
(Jackson, 2007). But the limiting factor is the heat generated
during grinding and the increase in heat associated with
higher wheel speeds. The known way to handle this issue is to
have a suitable coolant that can manage the heat generated
during grinding (Webster and Gruen, 2008).
Coolant suppliers also provide a lot of technical solutions.
The associated issue in coolants is that most high performing
coolants are synthetic in nature and they end up in polluting
the atmosphere. Most of them are not disposable directly into
the environment (Ramesh et al., 2003). Tso and Huang
(2007) discuss some approaches to reduce the severity of
coolants in the workplace environment. Torre and
Bustamante (2006) highlight the need for environmental
practices in auto industry. Hence, many industries have a
need to evaluate coolants either for improving their
productivity or to switch to eco-friendly coolants to take
care of the environment.
The current issue and full text archive of this journal is available at
www.emeraldinsight.com/0036-8792.htm
But the major issue in any mass production industry like
automobile industry is that it is a continuous process industry,
mostly running on a centralized coolant system. Even if a new
grinding wheel and a new coolant are available, evaluating them
directly on the production line is quite tedious and presents
practical difficulties. This is because, the entire production line
has to be stopped for a while to flush off the coolant in use and to
refill with the new coolant. Needelman et al. (1989) have
described the difficulties faced by an auto major when their
coolant got contaminated. Even sorting out an issue with a
regularly used coolant causes severe loss of production. So,
planning a similar intervention with regular production
schedule for coolant evaluations is almost an unpleasant duty
for the shopfloor person. Also, the quantity of coolant required
for trials is quite high, running into thousands of litres. If the
new coolant under trial does not perform well, then again the
entire coolant line has to be flushed, coolant central tank has to
be cleaned and then coolant changeover has to be effected. This
is quite a laborious process.
On the other hand, if we attempt to use the predictive
models available in literature, it is usually observed that
according to the assumptions made to develop the model, the
results vary from actual performance.
There is still scope for a quick performance test that closely
correlates to actual grinding conditions. To meet this need,
a grinding performance simulator is developed and tested for
its suitability for coolant evaluation. It is demonstrated with
results that this simulator can be used for a quick evaluation
of coolants for grinding.

Industrial Lubrication and Tribology

2. Evaluation of coolants-literature survey
64/4 (2012) 224– 229
q Emerald Group Publishing Limited [ISSN 0036-8792]
Coolants serve to remove the heat due to grinding and safeguard
[DOI 10.1108/00368791211232771] the workpiece from thermal damage. They remove the debris

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 A performance simulator for grinding coolant evaluation
T.D. Lavanya and V.E. Annamalai
and thereby help to eliminate inaccuracies in dimensions.
Coolants can help to reduce the wheel dressing needs. Any
grinding wheel is made of abrasives (that cut) and the bonding
material (that holds the grains intact). The coolant affects the
strength of the bond and thereby indirectly reduces the duration
to which an abrasive can perform, leading to premature failure
of the bonds (Webzell, 2004). Thus, coolants can have both
positive and negative impact on the grinding performance of a
given wheel-coolant combination.
Hence, it is important to estimate the effect of a coolant on
the grinding performance, even before the grinding operation
commences. To this effect, there have been many studies to
evaluate a coolant and provide guidelines in selecting a proper
coolant in order to achieve a specific grinding performance.
2.1 Actual grinding tests
Coolants have been traditionally evaluated by actual grinding
performance tests. Ghosh et al. (2009) have shown that
efficient use of coolants can enhance the grinding
performance of CBN wheels while grinding bearing steel by
high efficiency deep grinding process.
2.2 Estimating and modeling the flow pattern of
coolants
The quantity of fluid required for grinding and the method of
application have been addressed by assessing the flow rates
and flow patterns. Morgan et al. (2008) have shown that
computational fluid dynamics (CFD) can be used to model
the coolant flow in the wheel pores. Their results suggest that
supply flow rate needs to be four times the achievable “useful”
flow rate. Extra flow rate is wasted. It is shown that jet velocity
and jet flow rate can be separately specified. Improved system
design allows “actual” useful flow rate to approach
“achievable” useful flow rate.
Gao and Tao (2001) have proposed a method in which an
injection of stream is used to repel the coolant to generate an
area suitable for optical measurement. An experimental testing
system is developed to identify the optimum operational
conditions for design enhancement and to facilitate the
validation. The system enables in-process surface profile
measurement for quality control of workpieces during
precision machining.
Quick point grinding is a new type of high speed grinding
process with a point contact zone and lower grinding power.
Because of the thin super abrasive grinding wheel, the air barrier
effect is weakened. Through the analysis of the dynamic
pressure and velocity distribution in the air layer surrounding
the rotating grinding wheel, Xiu et al. (2006) have shown that
the flow rate of coolant and air can be predicted by a suitable
mathematical model.
Herzenstiel et al. (2007) describe a method to understand the
interaction of process and machine during high-performance
grinding and suggest a comprehensive simulation concept.
Griniashvili et al. (2004) have developed a mathematical
model for coolant flow rate between a rotating grinding wheel
and a workpiece. It has been shown that the useful flow that
passes through the contact zone is a function of spindle power
for fluid acceleration, wheel speed and delivery nozzle jet
velocity. With this model, it is possible to determine a suitable
value of nozzle outlet gap to achieve a required fluid film
thickness in the grinding zone.
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Industrial Lubrication and Tribology
Volume 64 · Number 4 · 2012 · 224 –229
2.3 Estimating the convective heat transfer coefficient
The overall effectiveness of the fluid is determined by the ability
of the fluid to remove heat from the contact region. Lin et al.
(2009) have used the principles of finite element method
(FEM) and obtained a three dimensional topology map of the
temperature distribution. The work is based on the theory of
fluid dynamics and on analytical models that are used to
describe the heat transfers.
Moulik et al. (2001) have developed a FEM to calculate the
temperatures and stresses arising due to a moving heat source
and applied this method to estimate grinding temperatures
and thermal stresses.
2.4 Non-grinding performance tests
Ge et al. (2004) suggest:
.
a tapping torque test; and
.
a four ball test.
The coolant effect in simple tapping operation is used to
estimate its effectiveness in cooling in an actual machining
operation. In a four ball test, the results are repeatable and the
test is simple, but there is very little correlation with actual
grinding condition result.
2.5 Need for a better method
As seen above, coolants have been evaluated either by actual
grinding tests or by predictive models. Of these, actual
grinding tests are costly and not affordable. This is a post-
operative test that can be used only for repeat performance of
known coolants. This cannot be used for predicting the
performance of new coolants.
On the other hand, if we attempt to use the predictive models
available in literature, the results vary from actual performance
according to the assumptions made to develop the model. Many
methods aim at selectively testing specific properties like
corrosion resistance of the coolant and they have no correlation
to grinding performance. There is still scope for a quick
performance test that closely correlates to actual grinding
conditions and can be used for a quick evaluation of coolants for
grinding.
3. Approach followed
Since previous results showed that performance test is closer
to reality, it was aimed at developing a suitable performance
simulator. In a grinding process, the abrasive, by virtue of
rotation, keeps tracking the same path on workpiece multiple
times. Hence, a rub testing machine was developed as shown
in Figure 1.
3.1 Constructional features of the simulator
Normal rub testing machines have a standard disc and a pin that
is held against the rotating disc. The wear is usually measured by
tracking the wear on the pin, measured as change in the height of
the pin, in micrometers. This is acceptable in normal wear test
because both the pin and the disc are flat and are in total contact,
with the wear proceeding gradually, by mechanisms aided by
friction between the two materials.
In our case, since one of the components is abrasive, the wear
is not uniform. Wherever an abrasive meets the disc, there will
be deeper grooves and wherever the bond of the wheel meets the
disc, there will be less wear. Hence, measuring the overall height
loss of the pin may not be real representation of the wear. We
need to measure the weight loss, instead of the height loss.
 A performance simulator for grinding coolant evaluation
T.D. Lavanya and V.E. Annamalai
Figure 1 Performance simulator
Work Piece groove
Wheel holder
Turn table
Hence, the machine was modified in such a way that both the
pin and the disc can be removed and evaluated for weight loss.
This also permits closer comparison with actual grinding
evaluation methods like grinding ratio (GR). A sensitive four
decimal weighing scale (that can measure 0.0001 mg) was used.
Since the range of the balance for such an accuracy was 200 g,
the workpiece had to be designed in such a way that its overall
weight does not exceed 200 g. Hence workpieces were made in
the form of rings. Size of the workpiece was chosen as: 150 mm
outer diameter, 35 mm thick and 120 mm inner diameter.
The equipment had a rotating base with slots, that could
exactly house these rings concentrically. The depth of the slot is
such that it can house the workpiece ring and allow a small
thickness of the workpiece ring to project above the plate. The
workpiece ring can be housed in the slot of the base plate and
rotated. A supporting pillar is attached to the machine with
provision to hold small cylindrical pieces of grinding wheel and
press against the workpiece ring at any desired position. Size of
the abrasive wheel/mounted grain: cylinder was 10 mm
diameter and 35 mm height. The grinding wheel piece can be
housed in the holder of the pillar and pressed against the
rotating ring. The abrasive piece holder can also be loaded with
dead weights of the order of a few grams. A coolant pump can
also be incorporated, but for the experiments, coolant pump of
other machinery was used and coolant taken through hose pipe.
3.2 Experimental work in simulator
The experiment was done with miniature wheel fabricated to
the size of the grain holder (miniature wheel can be either
fabricated or can be shaped from worn out wheel). The
workpiece of various materials like Cast iron (CI), High speed
steel (HSS) and mild steel (MS) was made into ring forms to
be held in the simulator. The ring was positioned on the table,
allowed to rotate and subjected to abrasive cutting action by
the wheel piece pressing over it from the holder. Coolant was
pumped from the coolant pump of cylindrical grinding
machine, and applied to the ring wheel interface, through
hose pipes. This ensures same amount of coolant flow for
both the simulator experiments as well as the cylindrical
grinding experiments (planned later).
The weight loss of the workpiece ring and the weight loss in
the wheel piece after the test, were evaluated. The small size
of the planned abrasive workpiece and the workpiece ring
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Industrial Lubrication and Tribology
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facilitated weighing in a scale with 0.0001 mg accuracy.
GR was estimated as material removed/wheel loss. Material
removal rate (MRR) was evaluated as material removed/time.
3.3 Experimental verification in grinding machine
For verification purposes, the same wheel workpiece
combination was evaluated in a cylindrical grinding
machine. The whole grinding wheel of the same abrasive
type and composition (as used in simulator) and the same
workpiece material in the required larger sizes, were used in
the cylindrical grinding test.
Since machine to machine comparison may not be realistic,
we tested the ability of the simulator to differentiate between
two conditions that yield different grinding performance.
Hence, in any experiment, two conditions would be evaluated
in cylindrical grinding and the same two conditions would be
evaluated in simulator and then the trend analyzed. For
obvious properties of abrasives, the simulator experiment
alone was done. More details are given in the next section.
4. Validation of simulator
Various hypotheses were verified for validation of equipment
as explained below.
4.1 Coarse grits vs fine grits
It is well known that coarse grains give coarser finish, (higher Ra)
and fine grains give finer finish, (lesser Ra). Harder bonds may
hold the grain for longer time. As the grain becomes more blunt
with continuous grinding, it will spoil the finish. Hence, wheel
hardness grade will influence the surface finish generated. To
avoid the effect of bond, the abrasive grains were mounted on
epoxy mounts just as is done for any microscopic polishing. The
size of the mount was made to fit the holder of the equipment
(10 mm dia and 35 mm height).
The procedure for mounting can be explained with
reference to Figure 2, showing two parts of a plastic mold.
Silicon grease should be applied to the inner sides of both top
and bottom mold. A single layer of pre-weighed grains should
be placed onto the projected face of the bottom mold. Epoxy
resin and Araldite hardener should be mixed in 80-20 ratio,
respectively. Top mold should be placed on the bottom mold,
fixed tight and epoxy resin mixture should be poured into the
mold. The resin can be cured either by heating it at 808C for
2 h or by leaving it undisturbed for 12 h. After curing, the
bottom mold is stripped off from the setup by gentle tapping
and the grain mount is ejected carefully by pushing by thumb
pressure. This grain mount serves as the grinding wheel
equivalent for our test purpose.
Grain mounts of grits 30, 36 and 80 of aluminium oxide
abrasives were made and evaluated in the simulator set up
using cast iron rings as workpiece. Details of experiment are
shown in Table I.
The surface roughness was evaluated for Ra and Rt. The
results are shown in Table II and Figure 3. From Figure 3, it is
clear that coarser grain gives coarser Ra, Rt and finer grain gives
finer Ra, Rt. This is in agreement with the expected trend.
Hence the simulator is capable of differentiating between
coarseness of grains.
4.2 Water and synthetic coolant
Two experiments were done by changing the coolants,
using water and cimcool.
 A performance simulator for grinding coolant evaluation Industrial Lubrication and Tribology
T.D. Lavanya and V.E. Annamalai Volume 64 · Number 4 · 2012 · 224 –229

Figure 2 Mold setup for mounting grains with epoxy resin Figure 3 Effect of grit size on surface finish in Simulator validation test
10 mm dia Grit size versus surface finish
25

surface finish in microns

Ra Rt
20

15

10

0
ABV 30 ABV 36 ABV 80
35 m Grit size
heigh

Table III Experimental setup for coolant validation in simulator

Wheel A60 L5 V10

Wheel size (mm) 10 OD*35 T
Workpiece (rpm) 150
Grinding time 2 min
Workpiece HSS
Workpiece size (mm) 150 OD*35*120 ID
Coolants Water and cimcool

Tight fitting lid that can be opene Table IV Results for coolant simulation
to push the mold out after solidifica Wheel Coolant GR MRR min2 1
A60 L5 V10 Water 0.11 0.032
A60 L5 V10 Cimcool 0.61 0.078
Table I Experimental setup for validation of grit size in simulator

Grain mount 30, 36 and 80 grit of Brown Aloxide

Mount size (mm) Ten OD*35 thickness 4.3 Comparison with actual grinding results
Workpiece (rpm) 150 However, these simulator results are cross validated by
Grinding time 2 min comparing the results obtained in actual performance tests in
Workpiece CI cylindrical grinding. The test set up for cylindrical grinding is
Workpiece size (mm) 150 OD*35 T*120 ID described in Table V.
Coolant Water
The evaluation is done as below.
The cylindrical workpiece is 5 mm thick and is held between
centres, and positioned in such a way that the axes of both the
wheel and the workpiece are parallel. When the feed is given,
Table II Ra and Rt for various grits (in microns) the wheel head advances towards the work. Since the workpiece
Grain Ra Rt is 5 mm thick and the wheel is 15 mm thick, the workpiece
literally plunges into the wheel, creating a groove on the wheel’s
ABV 30 2.914 22.65 cutting face. The initial and final volumes of the wheel and the
ABV 36 1.588 14.1 workpiece are measured geometrically. The wheels were
ABV 80 0.4207 4.6

Table V Experimental setup for cylindrical grinding

The grinding results were calculated as below: Machine type Cylindrical grinding
1 GR – weight of work loss/weight of wheel loss.
Work piece HSS Size-100 mm dia
2 Metal removal rate (MRR) – weight of work loss/grinding
and 5 mm thick
time per pass.
Wheel grading A60 L5 V10 (brown aluminum
Table III shows the experimental conditions of the simulator. oxide grain, grit 60, vitrified wheel, structure 5)
The results are tabulated in Table IV. Wheel size 300 mm dia, 15 mm thick and 127 mm arbor dia
From Table IV it is clear that cimcool gives better performance Test conditions Plunge grinding at the feed rate of 2 mm/min
than water in life and metal removal rate. This is the expected Grinding time 4 min test
trend. Hence the simulator is capable of differentiating between Coolant Water and cimcool
coolants also.

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 A performance simulator for grinding coolant evaluation Industrial Lubrication and Tribology
T.D. Lavanya and V.E. Annamalai Volume 64 · Number 4 · 2012 · 224 –229

evaluated for GR and metal removal rate (MRR). GR refers to Figure 5 Effect of coolant type on MRR in Simulator experiments
the volume of material removed, per unit volume of the grinding
Effect of coolant change on
wheel lost. MRR indicates the volume of material removed per
MRR in simulator
unit of time. The calculations are as below (Krueger et al., 0.09
2000):
. GR – volume of work loss/volume of wheel loss. 0.08
.
Metal removal rate (MRR) – volume of work loss/ simulator
grinding time. 0.07

Material Removal Rate

The results are tabulated in Table VI. 0.06
From Table VI, it is seen that cimcool performs better than
water in life and material removal rate. The same trend is seen 0.05
in the simulator also.
Hence the simulator is capable of differentiating between 0.04
coolants also.
Compiling data on simulator and grinding machine, for GR, 0.03
we get a trend graph as in Figure 4. From Figure 4, it can be seen
0.02
that the trend of change in GR of the simulator is similar to the
trend displayed by actual grinding results. The difference in 0.01
slopes may be attributed to the differences in GR calculations
(machine being volumetric GR and the simulator being weight 0
based GR). However, the trend is indicative of what can be water cimcool
expected if the coolant is changed from water to cimcool. Coolant Type
Compiling data on MRR, Figure 5 shows the trend in MRR
change in simulator and Figure 6 shows the trend in MRR
change in the grinding machine, with change in coolant type. As Figure 6 Effect of coolant type on MRR in grinding machine
can be seen, both graphs show similar trend. experiments
Thus, the simulator is capable of indicating the expectable
trend in GR and MRR if a coolant is changed. It is also capable Effect of coolant change on MRR
of displaying surface finish values. in machine
5.8
Table VI Cylindrical grinding results for coolant machine
5.75
Wheel Coolant GR MRR min2 1
5.7
A60 L5 V10 Water 1.24 5.48
Material Removal Rate

5.65
A60 L5 V10 Cimcool 1.79 5.75
5.6

5.55
Figure 4 Change in GR with coolant change in simulator and grinding
5.5
machine
5.45
Effect of coolant change
2 5.4
water
1.8 5.35
cimcool
1.6 5.3
water cimcool
1.4
Coolant type
Grinding Ratio

1.2

1 5. Utility for automotive industries

0.8 With the help of such a simulator, one can have a first cut
estimation of what can be expected if a coolant is changed.
0.6 This could be useful as a pre-qualifier for full scale shopfloor
trials. Thus, it is possible to minimize the actual shopfloor
0.4
trials on new coolants. As a wheel manufacturer, the wheel
0.2 samples for test can be had from fresh mix and wheels can be
fabricated for required sizes. But as a user, one may not have
0 this facility but still, they can create the required wheel sample
simulator machine from the left over portion of the used wheel. This is because,
Test equipment in any grinding wheel, at least one third is used for clamping

228
 A performance simulator for grinding coolant evaluation
T.D. Lavanya and V.E. Annamalai
and the rest is consumed for grinding. After the grinding
wheel is fully consumed, it still has a sizable portion, that was
originally used for clamping in flanges.
6. Conclusion
The simulator described above is capable of indicating trends
and differentiating performances of abrasives and coolants.
The results are in agreement with the performance trends
observed in cylindrical grinding.
The method suggested in this paper using this simulator
can be applied for predicting the behaviour of a coolant
change in grinding.
This method can be customized for various grinding
machines, by generating a correlation factor through sufficient
number of tests and comparison.
This test offers the following advantages:
.
Very simple and easy to evaluate.
.
Resembles actual grinding because of estimating GR and
MRR and not depending on height loss in microns
normally used by rub tests.
.
Consumes less coolant and avoids the need for massive
cleaning of grinding machine, for the sake of evaluating a
new coolant.
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Industrial Lubrication and Tribology
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About the authors
T.D. Lavanya is currently Deputy Manager at SAK
Abrasives, Chennai. She is a Post graduate in Ceramics,
working on various aspects of grinding wheel design and
performance improvement. This work is part of her PhD
study on coolants undertaken at Birla Institute of Science and
Technology (BITS), Pilani, India.
Dr V.E. Annamalai received his doctorate from Indian
Institute of Technology, Madras and is Professor of
Mechanical Engineering at SSN College of Engineering,
Chennai, India. Prior to this, he was Vice President Technical
at Carborundum Universal Limited, heading the Abrasive
Research Centre, carrying out research on abrasives and
abrasive Products. Dr V.E. Annamalai is the corresponding
author and can be contacted at: annamalaive@ssn.edu.in