ECM: Reducing the Use of Environmentally Hazardous Fluids in Grinding

9528679液位研磨所用的液体会对环境造成危害。它们对机房人员的健康造成不利影响，含有金属碎屑的磨削液是一种污染源，必须妥善处理。这项研究的目标是开发各种策略，以实现干法或减少流体研磨，这将在不同的情况下工作。研究方法包括：(1)改进砂轮设计，例如，具有最佳晶粒度和间距的立方氮化硼砂轮，增强导热结合；(2)优化磨削条件，以减少液体使用量；(3)采用替代冷却策略，例如基于涡流管的“冷气枪”、蒸发冷却、内部砂轮冷却，以及其他方法。这些策略将通过实验和分析进行探索。实验的结果将有两个方面：(A)量化各种策略在消除或减少液体使用方面的有效性，以及(B)提供作为模型输入和验证所需的数据。在给定测量的磨削功率的情况下，分析模型将预测温度。有了这些信息，该模型可以用于指导车轮设计的选择，解释实验结果，建议新的实验条件进行探索，从而最终指导工业过程设计。该项目的最后阶段将是“概念验证”，即在与工业合作伙伴合作选择的实际研磨应用中，使用和优化最有利的策略，以减少研磨过程对环境的影响。含有金属碎屑的磨削液是一个一次性问题，因此增加了制造成本。如果可以通过替代冷却策略在不影响性能的情况下减少磨削液的使用量，则可以促进“干”金属屑的回收。如果成功，研磨业对环境问题的贡献可能会更小。

9528679 Lavine The fluids used in grinding present an environmental hazard. They adversely affect the health of personnel in the machine room, and used grinding fluid containing metal chips is a source of pollution which must be properly disposed of. The objective of this research is to develop a variety of strategies for enabling dry or reduced fluid grinding which will work in different situations. Research approaches are to include: (1) improving the wheel design, e.g., Cubic Boron Nitride wheels with optimal grain size and spacing, enhanced thermal conductivity bonds; (2) optimizing the grinding conditions with the goal of reducing fluid usage; (3) using alternative cooling strategies, e.g. "cold air guns" based on vortex tubes, evaporative cooling, internal wheel cooling, and other approaches. These strategies are to be explored experimentally and analytically. The results of the experiments will be twofold: (a) quantify the efficacy of the various strategies in eliminating or reducing fluid usage, and (b) provide the data needed as input to, and validation of, the model. The analytical model will predict temperatures, given the measured grinding power. With this information, the model can be used in guiding the selection of wheel designs, explaining the experimental results, suggesting new experimental conditions to explore, and thus ultimately, guiding industrial process design. The final phase of the project will be the "proof of concept," in which the most favorable strategies are used and optimized for a realistic grinding application, chosen in cooperation with the industrial partners, for reducing the environmental impact of the grinding process. Grinding fluids containing metal chips pose a disposable problem and hence added manufacturing cost. If the use of grinding fluids can be reduced without adverse performance impact via alternate cooling strategies, recovery of "dry" metal chips can be facilitated. If successful, the grinding industry could be on e less contributor to the environmental problems.