Coolant Delivery System for Creep-Feed Grinding - Mechanical ...

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Dalhousie University MECH 4010 – Design Project I – Fall Term Report Former Masters candidate Joachim Steffen upgraded the coolant system on the Blohm Planomat to produce a coherent jet. The fan-like spray of the stock coolant nozzle was replaced with a precise jet of 0.5 degree coherency 1 . A high pressure wheel cleaning system was also implemented, using coolant sprayed perpendicular to the wheel to remove debris from the wheel surface. The coherent jet system resulted in an increase in the achievable MRR of up to 60% over the stock nozzle system. The wheel cleaning system nearly eliminated the problem of premature wheel breakdown. Later tests were performed by Masters candidate Rishad Irani, in which he implemented a high pressure jet system in place of Steffen’s coherent jet system. This resulted in further increases in the achievable MRR which were found to be an additional 40% over the improvement of the coherent jet system. Therefore, based on these research findings it was determined that a high pressure coherent jet system running in conjunction with a high pressure wheel cleaning system would have potential to produce further improvements. For this reason it is believed that a system incorporating these characteristics would be useful in attempting to optimize the coolant delivery for creep feed grinding. [Irani, 2006] [Steffen, 2004] 1 Degree of coherency = (Diameter of jet at nozzle exit) / (Diameter of jet at six inches from nozzle exit) 7
Dalhousie University MECH 4010 – Design Project I – Fall Term Report 2.0 Design Requirements The design criteria and performance goals of the project are as follows: • The size and geometry of the coolant system are to fit the existing grinding machine. • The coolant system will be easy to adjust, operate and maintain • One prototype will be produced • A set of operating instructions will be developed • All piping must be designed to handle operating pressures and secured to prevent any risk of injury. All safety features of the grinding machine will be retained. • The coolant delivery system must be robust, to handle potential daily use of the grinding machine. • The coolant system is required to handle several years of use with regular preventative maintenance • The coolant system will be made of quality materials, while keeping cost in consideration. The materials will be selected to suit their functional requirements in the system. • The project budget is $10,000. • The coolant system will be adaptable to flat and profile grinding. • The coolant will provide coverage of the entire cutting profile. • The amount of coolant will be minimized while still providing adequate cooling and lubrication. • The wheel cleaning system will be upgraded and integrated into the new design • Pressure and flow meters will be installed at various locations in the system. • The device will be built and testing will begin prior to March 21, 2007. 8
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Coolant Delivery System for Creep-Feed Grinding - Mechanical ...

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