Research Article Performance of Water-Based Zinc Oxide ...downloads.hindawi.com/journals/jnp/2014/175896.pdf · FacultyofMechanicalEngineering,UniversitiMalaysiaPahang,Pekan,Pahang,Malaysia

Research ArticlePerformance of Water-Based Zinc Oxide Nanoparticle Coolantduring Abrasive Grinding of Ductile Cast Iron

M M Rahman12 and K Kadirgama1

1 Faculty of Mechanical Engineering Universiti Malaysia Pahang 26600 Pekan Pahang Malaysia2 Automotive Engineering Centre Universiti Malaysia Pahang 26600 Pekan Pahang Malaysia

Correspondence should be addressed to M M Rahman mustafizurumpedumy

Received 6 November 2013 Revised 24 January 2014 Accepted 5 February 2014 Published 5 March 2014

Academic Editor Young-Seok Shon

Copyright copy 2014 M M Rahman and K Kadirgama This is an open access article distributed under the Creative CommonsAttribution License which permits unrestricted use distribution and reproduction in any medium provided the original work isproperly cited

This paper presents the performance of ductile cast iron grindingmachining usingwater-based zinc oxide nanoparticles as a coolantThe experimental data was utilized to develop the mathematical model for first- and second-order models The second order givesworthy performance of the grinding The results indicate that the optimum parameters for the grinding model are 20mmin tablespeed and 4243120583m depth of cut for single-pass grinding For multiple-pass grinding optimization is at a table speed equal to3511mmin and a depth of cut equal to 2978120583mThemodel fit was adequate and acceptable for sustainable grinding using a 015volume concentration of zinc oxide nanocoolantThis paper quantifies the impact of water-based ZnO nanoparticle coolant on theachieved surface quality It is concluded that the surface quality is the most influenced by the depth of cut(s) and table speed

1 Introduction

The automotive industry is one of the main users of groundcomponents Many solutions for grinding problems comefrom classical operations related to engine or transmissioncomponents Classical examples are crankshaft grinding andcamshaft grinding Since the automotive industry is one ofthe major drivers for grinding development it was chosen tobe the focus of this study Energy consumption by machiningand grinding processes has not been a concern for industrybecause the energy cost is much lower than the othercosts such as materials labor and tooling [1] The poorheat transfer properties of these conventional fluids poseserious problems to meet the present demands for minia-turization of systems and their effectiveness Earlier effortstowards the improvement of the thermophysical propertiesof conventional fluids by the suspension of micron-sizedmetallic particles were not successful due to sedimentationclogging erosion and increased pressure drop in the flowchannels of the heat exchangers and so forth A novel kindof heat transfer fluids known as ldquonanofluidsrdquo has significantlyhigher thermal conductivity compared to their base fluidsNanofluids are expected to offer appreciable improvements

in heat transfer capabilities [2] Grinding is one of the mostenergy intensive among all machining processes Grindingspecific energy is typically higher than the energy requiredfor melting the material Considering the large amountof grinding operations used by industry worldwide theimpact can be significant when we can improve the energyefficiency of the grinding process Furthermore the highenergy intensity of the grinding process is also the root causeof workpiece surface and subsurface damage such as burnwhite layer and residual stresses caused by the grinding oper-ation [3] Recent research has also shown how the finishedsurface quality imparted by a machining process may havesignificant impacts on other product life cycle stages besidesmanufacturing [4 5] Thus there is a need to change themanufacturing paradigm from minimizing resource costs tomaximizing resource efficiency (ie maximizing productionoutput or value added while minimizing resource inputs andcosts) both in the manufacture and use of products [6]Therehas beenmuch research to understand the role of the grindingtool in the grinding process Some expert systems exist wherethe grind process parameters [7] or the grinding tool [8 9]can be chosen for certain applications

Hindawi Publishing CorporationJournal of NanoparticlesVolume 2014 Article ID 175896 7 pageshttpdxdoiorg1011552014175896

2 Journal of Nanoparticles

Sustainability in abrasivemachining is a growing concernthat has been recognized by both academia and industry[10ndash12] However the essential aspect of abrasive tool designand its impact on process ecoefficiency have not yet beenexamined from a holistic perspective Nanofluids have thepotential to be the next generation of coolants due totheir significantly higher thermal conductivities In grindingto obtain performance the appropriate selection of a basefluid is very critical in the application of nanoparticle-basedlubricants as is proper selection of the cutting parametersfor machining [13] The thermal conductivity and the con-vection heat transfer coefficient of the fluid can be largelyenhanced by the suspended nanoparticles [14]The novel andadvanced concepts of coolants offer intriguing heat transfercharacteristics compared to conventional coolants There isconsiderable research on the superior heat transfer propertiesof nanofluids especially on the thermal conductivity andconvective heat transfer Eastman et al [15] Liu et al [16]Hwang et al [17] Yu et al [18] and Srinivasa Rao et al[19] observed great enhancements of the nanofluidsrsquo thermalconductivity compared to conventional coolants Enhance-ment of convective heat transfer was reported by Heris et al[20] Kim et al [21] Jung et al [22] and Sharma et al[23] Tribological research found that lubricating oil withnanoparticles would exhibit friction reduction propertiesBesides their application in industry especially in heating andcooling machining processes lubrication transportationenergy and electronics these features make nanofluids andnanoparticles useful and needing to be improved The heatbecomes concentrated in the grinding zone so that theworkpiece is heated at high temperature and there is thepossibility that the workpiece surface damage is due to thethermal effect [24]However there is littlework onnanofluid-based coolants in grinding processes since this is a new thingand there is a lack of consistency in the results regardingthermal properties [25 26] The objectives of this paper areto investigate the experimental performance of ductile castiron using water-based ZnO nanocoolant and to developmathematical models using the response-surface method

2 Materials and Method

21 ZnO Nanofluid Preparation Zinc oxide nanoparticlematerials were selected because zinc is commonly added tothe primary coolant to prevent corrosion A two-stepmethodwas used to prepare the nanofluid Basically nanoparticlesare first produced as a dry powder typically by inert-gascondensation which involves the vaporization of a sourcematerial in a vacuum chamber and subsequent condensationof the vapor into nanoparticles through collisions with thecontrolled pressure of an inert gas such as helium Theresulting nanoparticles are then dispersed into a fluid ina second processing step An advantage of this techniquein terms of eventual commercialization of nanofluids isthat the inert-gas condensation technique has already beenscaled up to economically produce tonnage quantities ofnanopowdersThus the dispersed nanoparticles which comein liquid form with a volume of one liter have 20 weight

concentration with a 30ndash40 nm particle size an 89 pH leveland density equal to 5600 kgm3 It is diluted to a 015volume concentration The conversion of the weight percentconcentration to volume concentration is expressed in (1)The second equation shows the dilution formula to determinehow much distilled water is required to dilute the initialnanofluid Consider

1205931=

120596120588119908

(120596100) 120588119908 + (1 minus (120596100)) 120588ZnO (1)

where 1205931is the initial volume concentration 120596 is the weight

percent of nanoparticles 120588119908is the density of water and 120588ZnO

is the density of the nanoparticlesFor a two-phase system some important issues have to be

faced One of the most important issues is the stability of thenanofluids and it remains a considerable challenge to achievethe desired stability of the nanofluids To achieve stability inthe dilution the solution needs to be stirred continuously forone hour with the mixture set to 1000 rpm Nanoparticleshave a tendency to be aggregated The use of surfactantsis an important technique in enhancing the stability ofnanoparticles in fluids However the functionality of thesurfactants under high temperature is also a major concernespecially for high-temperature applications Therefore nosurfactant is applied in this study

22 Design of Experiments Thedesign of experiments (DOE)techniques enable designers to determine simultaneouslythe individual and interactive effects of many factors thatcould affect the output results The statistical experimentaldesigns (response-surface designs (RSM)) are most widelyused in optimization experiments The central compositedesign (CCD) is themost popular of themany classes of RSMdesigns due to the properties listed in Table 1

A CCD can run sequentially It can be naturally parti-tioned into two subsets of points the first subset estimateslinear and two-factor interaction effects while the secondestimates curvature effects The second subset need not berun when analysis of the data from the first subset indicatesthe absence of significant curvature effects CCDs are alsovery efficient providing much information on experimentalvariable effects and the overall experimental errors in a min-imum number of required runs They are very flexible Thereis good commercial software available to help with designingand analyzing response-surface experiments Table 1 showsthe DOE table generated using statistical software An exper-iment was conducted based on the DOE table and differenttypes of coolant zinc oxide (ZnO) nanocoolant with a 015volume concentration and a 5 volume concentration con-ventional soluble oil water-based coolant Constant grindingwheels of vitrified bond aluminum oxide (PSA-60JBV) wereused Two types of grinding were considered single passand multiple pass set to ten passes Figure 1 presents thedifferent isometric views of workpieceThe dimensions of theworkpiece are 80mm times 35mm times 20mm

23 Grinding Process The grinding process was undertakenusing a Supertec precision grinding machine model STP-102ADCII A vitrified bond aluminum oxide grinding wheel

Journal of Nanoparticles 3

Table 1 Design of experiment

Specimen Table speed (mmin) Depth of cut (120583m)A 20 20B 20 40C 20 60D 30 20E 30 40F 30 60G 40 20H 40 40I 40 60

Top view

Side view Front view

80mm

20mm 20mm

35mm

35mm

80mm

Figure 1 The workpiece and its different isometric views

(PSA-60JBV) with an average abrasive size of 60 grains wasused The workpiece material was block ductile iron witha carbon content of 35ndash39 and average hardness of 110-Rockwell C The width and length of the workpiece surfacefor grinding were 35mm and 80mm respectively First theworkpiece was clamped onto a clamper jaw since cast ironis not attracted to the magnet field Then the zero pointof the 119911-axis was found by grinding the disc slowly untilthere were some sparks After that the coolant was sprayeddirectly onto the workpiece to ensure that the temperatureof the workpiece was equivalent to the temperature of thecoolant and as a precaution to achieve an exact value of risingtemperature Then the workpiece speed was calibrated usinga tachometer The model STP-102ADCII can be controlledand uses a hydraulic system to move left and rightThe speedis controlled by a control valve however there is no speeddisplay So in this research calibration of the table speedusing a tachometer had to be undertaken and the speed wasset at 20mmmin 30mmmin and 40mmmin

3 Results and Discussion

This section presents the performance characteristics ofductile cast iron grinding with a conventional coolant anda water-based zinc oxide nanocoolant The mathematicalmodels for the prediction of the material removal rate andtool wear rates are presented in this section These modelswere developed using the accumulated data obtained fromexperiments using a conventional soluble oil coolant and

0002004006008

01012014016018

A B C D E F G H ISpecimen

Single-pass nanocoolantSingle-pass conventional coolantMultiple-pass nanocoolantMultiple-pass conventional coolant

MRR

(cm

3s)

Figure 2 Material removal rate for each coolant and type ofgrinding

a zinc oxide nanocoolant The significance and adequacy ofthese models are verified by analysis of variance using theresponse-surface method

31Material Removal Rate Thematerial removal rate (MRR)for conventional coolant and nanocoolant as well as forsingle and multipass grinding processes is represented inTable 2 The experiments were conducted nine times withvarious combinations of table speed and depth of cut A5 volume concentration of soluble oil coolant and a 015volume concentration of zinc oxide nanocoolant were usedin this study It can be observed that the minimum MRRin single-pass grinding using the conventional coolant was0024 cm3s however the minimum material removal ratewas 0020 cm3s for the zinc oxide nanocoolant with thecombination of the table speed and depth of cut On the otherhand the maximum value is 0155 cm3s and 0122 cm3s forthe conventional coolant and the zinc oxide nanocoolantrespectively They were slightly different in multiple-passgrinding The minimum MRR in multiple-pass grindingusing a conventional coolant was 0032 cm3s however theminimumMRR was 0023 cm3s for zinc oxide nanocoolantFigure 2 shows the MRR value effect arising from variouscombinations of the factors table speed depth of cut typeof grinding and type of coolant Multiple-pass grinding hasa higherMRR compared to the single pass due to the grindingwheel only passing over the specimen once On the otherhand for multiple-pass grinding the grinding wheel passesten times

However when using zinc oxide nanocoolant the MRRwas slightly lower than that of the conventional coolantThis is due to the nanoparticle having exceptional tribo-logical properties which can reduce friction under extremepressure conditions This is supported by the findings fromWu et al [27] Analysis of variance (ANOVA) for the firstorder was undertaken to model and predict the MRR forsingle-pass grinding and multiple-pass grinding using zincoxide nanocoolant and is presented in Table 2 The adequacyof the first-order model is verified using the 119875 value of


Table 2 Material removal rate for each coolant and type of grinding

Specimen Table speed (ms) Depth of cut (120583m)Material removal rate (cm3s)

Single pass Multiple passConventional coolant Nanocoolant Conventional coolant Nanocoolant

A 20 20 0024 0020 0032 0023B 20 40 0049 0041 0056 0045C 20 60 0072 0061 0081 0071D 30 20 0031 0025 0041 0031E 30 40 0065 0053 0073 0063F 30 60 0096 0081 0105 0093G 40 20 0045 0037 0063 0046H 40 40 0096 0079 0112 0095I 40 60 0155 0122 0159 0156

Table 3 ANOVA results for first-order and water-based zinc oxidenanocoolant

Source Degree of freedom Sum of sq 119865-static 119875 valueSingle-pass grinding

Model 3 000824733 984364 lt0001Error 6 000016757C total 9 000841490Interaction 2Lack-of-fit 5 000016307 72474 02745Pure error 1 000000450Total 6 000016757

Multiple-pass grindingModel 5 1960468930 2623551 lt0001Error 4 014945158C total 9 1975414088Interaction 2Lack-of-fit 3 014878180 444271 01134Pure error 1 000066978Total 4 014945158

the lack-of-fit At a level of confidence of 95 the modelswere checked for their adequacy Based on ANOVA for theprediction of MRR in both single-pass and multiple-passgrinding using zinc oxidewater-based nanocoolant as shownin Table 3 the models are adequate due to the fact that thelack-of-fit of the 119875 values is insignificant where the valueis 02745 for single-pass grinding and 01134 for multiple-pass grinding which are larger than 005 This implies thatboth models could be of good fit and are adequate Thusthe first-order linear equations used to predict the MRR insingle- and multiple-pass grinding using zinc oxide water-based nanocoolant are expressed as the following equationsfor single- and multiple-pass grinding respectively

MRR1015840First-order single pass = 00569 + 0019331199091

+ 0030331199092+ 0011119909

11199092

(2)

Table 4 ANOVA results for second-order and water-based zincoxide nanocoolant




MRR1015840Fist-order multipass = 03914 minus 171845 sdot 1199091

+ 0055641199092minus 0084825119909

11199092

(3)

Even though the first-order model was found to beadequate the second-order model was postulated to extendthe variablesrsquo range in obtaining the relationship betweenthe MRR and the machining independent variables Theadequacy of the first-ordermodel is verified using the119875 valueof lack-of-fit At a level of confidence of 95 themodels werechecked for their adequacy Based on ANOVA the resultsfor the prediction of MRR in both single-pass and multiple-pass grinding using 015 volume concentration zinc oxidewater-based nanocoolant are presented in Table 4Themodelis adequate due to the fact that the 119875 values of lack-of-fitare insignificant The lack-of-fit value is 05504 for single-pass grinding and 01313 for multiple-pass grinding which arelarger than 005This implies that both models are of good fitand are adequate The second-order mathematical equationused to predict the MRR in single-pass and multiple-pass


0002004006008

01012014016018



MRR

(cm

3s)

Figure 3 Comparison between the experimental and predictedresults for both single- and multiple-pass grinding

grinding for zinc oxide water-based nanocoolant can beexpressed as the following equations respectively

MRR2nd-order single pass = 005193 minus 0019333 sdot 1199091 + 0030331199092

+ 001111990911199092+ 0007643119909

2

1

+ 000064291199092

2

(4)

MRR2nd-order multipass = 55109 minus 171851199091 + 055641199092

minus 00848311990911199092minus 0120473119909

2

1

minus 012821199092

2

(5)

To test whether the model is adequate and fit to predictthe MRR in both single-pass and multiple-pass grindingFigure 3 illustrates the relationship between the experimentaland predicted values for both single- and multiple-passgrinding The predicted values and measured values areclosely related indicating that the developed model couldbe effectively used to predict the MRR in both grindingprocesses in multiple-pass as well as single-pass grinding

32 Tool Wear Tool wear is usually the most relevantparameter inspected as it has direct influence on the finalproduct quality the machine tool performance and toollifetime During grinding cutting wheels remove materialfrom theworkpiece to achieve the required shape dimensionand surface roughness (finish) However wear occurs duringthe grinding action and will ultimately result in the failureof the cutting wheel When the tool wear reaches a certainlevel (03mm) the tool or active edge has to be replacedto guarantee the desired cutting action The tool wear wasmeasured in mm using a Taylorsurf profilometer Severalreadings were taken and the average was calculated Thereadings were taken at several points and the average wascalculated Figure 4 illustrates the tool wear for zinc oxidenanocoolant and conventional coolant In industry tool wear

0005

01015

02025

03035

04045

05

A B C D E F G H I

Tool

wea

r (m

m)

Specimen


Figure 4 Tool wear for each coolant and type of grinding

01234567



G-r

atio

Figure 5 G-ratio for different coolants and types of grinding

should be minimized to have a good quality finish precisionand costing It can be seen that the pattern of the wearincreases as the depth of cut and table speed increase formultiple-pass grindingThe nanocoolant reduces the wear byalmost 50 compared to the conventional coolantThis is dueto the nanocoolantrsquos reduced friction between the two contactsurfaces

33 G-Ratio G-ratio is defined as the volume of work mate-rial removed divided by the volume of wheel wear A high G-ratio indicates a low wheel wear rate [28] Figure 5 illustratesthe G-ratio for different coolants and types of grinding Itcan be observed that the type of coolant influences the G-ratio as well as the type of grinding Single-pass grindinggenerally exhibits a high G-ratio as shown in Figure 5 Theconventional coolant exhibits the worst wheel wear that isthe lowest G-ratio The G-ratio increases with the increasein the nanocoolant due to the formation of the slurry layerwhich can protect the grinding wheel from grindbondfractureThe nanocoolant enhances the thermal conductivityand convective heat transfer coefficient of the coolant whichexhibits improved load-carrying capacity and antiwear andfriction reduction properties [27]


4 Conclusion

(1) The grinding of ductile cast iron using Al2O3wheels

under water-based zinc oxide nanocoolant and con-ventional coolant was studied

(2) Compared to the water-based nanocoolant toolwear could be substantial compared to conventionalcoolant However nanocoolant could achieve thesame MRR without increasing the grinding forces

(3) During nanocoolant grinding a dense and hardslaggy layer was found on the wheel surface and couldbenefit the grinding performance

(4) Nanoparticles reduce the friction of the grindingwheel andworkpiece Less friction leading to low heatdensity generates and minimizes the tool wear

(5) Experimental results showed that theG-ratio could beimproved with high concentrations of nanocoolantThus the study of grinding using water-basednanocoolant focuses on advanced lubrication proper-ties

(6) Furthermore forthcoming work will investigate themachining parameters necessary for optimal qual-ity to determine the manufacturing resource costsrequired to maximize efficiency

Conflict of Interests

The authors declare that there is no conflict of interestsregarding the publication of this paper

Acknowledgments

The authors would like to thank Universiti Malaysia Pahangfor financial support under University Research Project noRDU120310 The authors also thank Mr Shabaruddin for hishelp and for preparing theworkpiece during the experimentalwork

References

[1] V Kumar and JW Sutherland ldquoSustainability of the automotiverecycling infrastructure review of current research and identifi-cation of future challengesrdquo International Journal of SustainableManufacturing vol 1 no 1-2 pp 145ndash167 2008

[2] A M Hussein R A Bakar K Kadirgama and K V SharmaldquoExperimental measurements of nanofluids thermal proper-tiesrdquo International Journal of Automotive and Mechanical Engi-neering vol 7 pp 850ndash863 2013

[3] S Malkin and C Guo Grinding Technology Theory and Appli-cations of Machining with Abrasives Industrial Press New YorkNY USA 2008

[4] M Helu A Vijayaraghavan and D Dornfeld ldquoEvaluatingthe relationship between use phase environmental impactsand manufacturing process precisionrdquo CIRP AnnalsmdashManu-facturing Technology vol 60 no 1 pp 49ndash52 2011

[5] R MrsquoSaoubi J C Outeiro H Chandrasekaran OW Dillon Jrand I S Jawahir ldquoA review of surface integrity in machiningand its impact on functional performance and life of machined

productsrdquo International Journal of Sustainable Manufacturingvol 1 no 1-2 pp 203ndash236 2008

[6] R Neugebauer R Wertheim and C Harzbecker ldquoEnergy andresource efficiency in themetal cutting industryrdquo in Proceedingsof the 8th Global Conference on Sustainable Manufacturing pp247ndash257 2011

[7] W B Rowe ldquoA generic intelligent control system for grindingrdquoComputer Integrated Manufacturing Systems vol 10 no 3 pp231ndash241 1997

[8] W B Rowe Y Li X Chen and B Mills ldquoAn intelligentmultiagent approach for selection of grinding conditionsrdquoCIRPAnnalsmdashManufacturing Technology vol 46 no 1 pp 233ndash2381997

[9] P Shore O Billing and V Puhasmagi ldquoA standard grindingwheel assessment method to support a sophisticated grindingknowledge based systemrdquo Key Engineering Materials vol 257-258 pp 285ndash290 2004

[10] B DenkenaM Reichstein N Kramer J Jacobsen andM JungldquoEco- and energy-efficient grinding processesrdquoKey EngineeringMaterials vol 291-292 pp 39ndash44 2005

[11] F Klocke B Linke B Meyer and A Roderburg ldquoSustainabilityaspects in centerless grindingrdquo in Proceedings of the Conferenceof Sustainable Life inManufacturing (SLIM rsquo10) pp 1ndash11 EgirdirTurkey June 2010

[12] J B Araujo and J F G Oliveira ldquoEvaluation of two competingmachining processes based on sustainability indicators Lever-aging technology for a sustainable worldrdquo in Proceedings of the19th CIRP Conference on Life Cycle Engineering pp 317ndash322Berkeley Calif USA May 2012

[13] P Hryniewicz A Z Szeri and S Jahanmir ldquoApplication oflubrication theory to fluid flow in grindingmdashpart II influence ofwheel and workpiece roughnessrdquo Journal of Tribology vol 123no 1 pp 101ndash107 2001

[14] S Malkin and C Guo ldquoThermal analysis of grinding method-ology 1966ndash1988rdquo Technometrics vol 31 pp 137ndash153 2007

[15] J A Eastman U S Choi L JThompson and S Lee ldquoEnhancedthermal conductivity through the development of nanofiuidsrdquoMaterials Research Society Symposium-V vol 457 pp 3ndash111996

[16] M-S Liu M C-C Lin I-T Huang and C-C WangldquoEnhancement of thermal conductivity with CuO for nanoflu-idsrdquoChemical Engineering and Technology vol 29 no 1 pp 72ndash77 2006

[17] Y Hwang H S Park J K Lee and W H Jung ldquoThermal con-ductivity and lubrication characteristics of nanofluidsrdquo CurrentApplied Physics vol 6 no 1 pp e67ndashe71 2006

[18] W Yu H Xie L Chen and Y Li ldquoInvestigation of thermal con-ductivity and viscosity of ethylene glycol based ZnO nanofluidrdquoThermochimica Acta vol 491 no 1-2 pp 92ndash96 2009

[19] G Srinivasa Rao K V Sharma S P Chary et al ldquoExperimentalstudy on heat transfer coefficient and friction factor of Al

2O3

nanofluid in a packed bed columnrdquo Journal of MechanicalEngineering and Sciences vol 1 pp 1ndash15 2011

[20] S Z Heris M N Esfahany and S G Etemad ldquoExperimen-tal investigation of convective heat transfer of Al

2O3water

nanofluid in circular tuberdquo International Journal of Heat andFluid Flow vol 28 no 2 pp 203ndash210 2007

[21] D Kim Y Kwon Y Cho et al ldquoConvective heat transfercharacteristics of nanofluids under laminar and turbulent flowconditionsrdquo Current Applied Physics vol 9 no 2 pp e119ndashe1232009


[22] J-Y Jung H-S Oh and H-Y Kwak ldquoForced convective heattransfer of nanofluids in microchannelsrdquo International Journalof Heat and Mass Transfer vol 52 no 1-2 pp 466ndash472 2009

[23] K V Sharma L S Sundar and P K Sarma ldquoEstimation ofheat transfer coefficient and friction factor in the transitionflowwith low volume concentration of Al

2O3nanofluid flowing

in a circular tube and with twisted tape insertrdquo InternationalCommunications in Heat and Mass Transfer vol 36 no 5 pp503ndash507 2009

[24] R Komanduri W R Reed Jr and B F Von Turkovich ldquoAnew technique of dressing and conditioning resin bondedsuperabrasive grinding wheelsrdquo CIRP AnnalsmdashManufacturingTechnology vol 29 no 1 pp 239ndash243 1980

[25] M Mahendran G C Lee K V Sharma and A ShahranildquoPerformance of evacuated tube solar collector using water-based TitaniumOxide (TiO

2) nanofluidrdquo Journal of Mechanical

Engineering and Sciences vol 3 pp 301ndash310 2012[26] K-F V Wong and T Kurma ldquoTransport properties of alumina

nanofluidsrdquo Nanotechnology vol 19 no 34 Article ID 3457022008

[27] J-HWu B S PhillipsW Jiang J H Sanders J S Zabinski andA PMalshe ldquoBio-inspired surface engineering and tribology ofMoS2overcoated cBN-TiN composite coatingrdquo Wear vol 261

no 5-6 pp 592ndash599 2006[28] L R Silva E C Bianchi R E Catai R Y Fusse TV Franca and

P R Aguiar ldquoStudy on the behavior of the Minimum quantitylubricantmdashMQL technique under different lubricating andcooling conditions when grinding ABNT 4340 steelrdquo Journal ofthe Brazilian Society ofMechanical Sciences and Engineering vol27 no 2 pp 192ndash199 2005

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MetallurgyJournal of


BioMed Research International

MaterialsJournal of


Nano

materials


Journal ofNanomaterials


Sustainability in abrasivemachining is a growing concernthat has been recognized by both academia and industry[10ndash12] However the essential aspect of abrasive tool designand its impact on process ecoefficiency have not yet beenexamined from a holistic perspective Nanofluids have thepotential to be the next generation of coolants due totheir significantly higher thermal conductivities In grindingto obtain performance the appropriate selection of a basefluid is very critical in the application of nanoparticle-basedlubricants as is proper selection of the cutting parametersfor machining [13] The thermal conductivity and the con-vection heat transfer coefficient of the fluid can be largelyenhanced by the suspended nanoparticles [14]The novel andadvanced concepts of coolants offer intriguing heat transfercharacteristics compared to conventional coolants There isconsiderable research on the superior heat transfer propertiesof nanofluids especially on the thermal conductivity andconvective heat transfer Eastman et al [15] Liu et al [16]Hwang et al [17] Yu et al [18] and Srinivasa Rao et al[19] observed great enhancements of the nanofluidsrsquo thermalconductivity compared to conventional coolants Enhance-ment of convective heat transfer was reported by Heris et al[20] Kim et al [21] Jung et al [22] and Sharma et al[23] Tribological research found that lubricating oil withnanoparticles would exhibit friction reduction propertiesBesides their application in industry especially in heating andcooling machining processes lubrication transportationenergy and electronics these features make nanofluids andnanoparticles useful and needing to be improved The heatbecomes concentrated in the grinding zone so that theworkpiece is heated at high temperature and there is thepossibility that the workpiece surface damage is due to thethermal effect [24]However there is littlework onnanofluid-based coolants in grinding processes since this is a new thingand there is a lack of consistency in the results regardingthermal properties [25 26] The objectives of this paper areto investigate the experimental performance of ductile castiron using water-based ZnO nanocoolant and to developmathematical models using the response-surface method

2 Materials and Method

21 ZnO Nanofluid Preparation Zinc oxide nanoparticlematerials were selected because zinc is commonly added tothe primary coolant to prevent corrosion A two-stepmethodwas used to prepare the nanofluid Basically nanoparticlesare first produced as a dry powder typically by inert-gascondensation which involves the vaporization of a sourcematerial in a vacuum chamber and subsequent condensationof the vapor into nanoparticles through collisions with thecontrolled pressure of an inert gas such as helium Theresulting nanoparticles are then dispersed into a fluid ina second processing step An advantage of this techniquein terms of eventual commercialization of nanofluids isthat the inert-gas condensation technique has already beenscaled up to economically produce tonnage quantities ofnanopowdersThus the dispersed nanoparticles which comein liquid form with a volume of one liter have 20 weight

concentration with a 30ndash40 nm particle size an 89 pH leveland density equal to 5600 kgm3 It is diluted to a 015volume concentration The conversion of the weight percentconcentration to volume concentration is expressed in (1)The second equation shows the dilution formula to determinehow much distilled water is required to dilute the initialnanofluid Consider

1205931=

120596120588119908

(120596100) 120588119908 + (1 minus (120596100)) 120588ZnO (1)

where 1205931is the initial volume concentration 120596 is the weight

percent of nanoparticles 120588119908is the density of water and 120588ZnO

is the density of the nanoparticlesFor a two-phase system some important issues have to be

faced One of the most important issues is the stability of thenanofluids and it remains a considerable challenge to achievethe desired stability of the nanofluids To achieve stability inthe dilution the solution needs to be stirred continuously forone hour with the mixture set to 1000 rpm Nanoparticleshave a tendency to be aggregated The use of surfactantsis an important technique in enhancing the stability ofnanoparticles in fluids However the functionality of thesurfactants under high temperature is also a major concernespecially for high-temperature applications Therefore nosurfactant is applied in this study

22 Design of Experiments Thedesign of experiments (DOE)techniques enable designers to determine simultaneouslythe individual and interactive effects of many factors thatcould affect the output results The statistical experimentaldesigns (response-surface designs (RSM)) are most widelyused in optimization experiments The central compositedesign (CCD) is themost popular of themany classes of RSMdesigns due to the properties listed in Table 1

A CCD can run sequentially It can be naturally parti-tioned into two subsets of points the first subset estimateslinear and two-factor interaction effects while the secondestimates curvature effects The second subset need not berun when analysis of the data from the first subset indicatesthe absence of significant curvature effects CCDs are alsovery efficient providing much information on experimentalvariable effects and the overall experimental errors in a min-imum number of required runs They are very flexible Thereis good commercial software available to help with designingand analyzing response-surface experiments Table 1 showsthe DOE table generated using statistical software An exper-iment was conducted based on the DOE table and differenttypes of coolant zinc oxide (ZnO) nanocoolant with a 015volume concentration and a 5 volume concentration con-ventional soluble oil water-based coolant Constant grindingwheels of vitrified bond aluminum oxide (PSA-60JBV) wereused Two types of grinding were considered single passand multiple pass set to ten passes Figure 1 presents thedifferent isometric views of workpieceThe dimensions of theworkpiece are 80mm times 35mm times 20mm

23 Grinding Process The grinding process was undertakenusing a Supertec precision grinding machine model STP-102ADCII A vitrified bond aluminum oxide grinding wheel




Top view


80mm

20mm 20mm

35mm

35mm

80mm





0002004006008

01012014016018



MRR

(cm

3s)









A 20 20 0024 0020 0032 0023B 20 40 0049 0041 0056 0045C 20 60 0072 0061 0081 0071D 30 20 0031 0025 0041 0031E 30 40 0065 0053 0073 0063F 30 60 0096 0081 0105 0093G 40 20 0045 0037 0063 0046H 40 40 0096 0079 0112 0095I 40 60 0155 0122 0159 0156







+ 0030331199092+ 0011119909

11199092

(2)






+ 0055641199092minus 0084825119909

11199092

(3)



0002004006008

01012014016018



MRR

(cm

3s)




+ 001111990911199092+ 0007643119909

2

1

+ 000064291199092

2

(4)


minus 00848311990911199092minus 0120473119909

2

1

minus 012821199092

2

(5)



0005

01015

02025

03035

04045

05

A B C D E F G H I

Tool

wea

r (m

m)

Specimen



01234567



G-r

atio





4 Conclusion










Acknowledgments


References





















2O3



2O3water























CeramicsJournal of







Biomaterials




Journal of


Journal of





CoatingsJournal of

Advances in








MaterialsJournal of


Nano

materials






Top view


80mm

20mm 20mm

35mm

35mm

80mm





0002004006008

01012014016018



MRR

(cm

3s)









A 20 20 0024 0020 0032 0023B 20 40 0049 0041 0056 0045C 20 60 0072 0061 0081 0071D 30 20 0031 0025 0041 0031E 30 40 0065 0053 0073 0063F 30 60 0096 0081 0105 0093G 40 20 0045 0037 0063 0046H 40 40 0096 0079 0112 0095I 40 60 0155 0122 0159 0156







+ 0030331199092+ 0011119909

11199092

(2)






+ 0055641199092minus 0084825119909

11199092

(3)



0002004006008

01012014016018



MRR

(cm

3s)




+ 001111990911199092+ 0007643119909

2

1

+ 000064291199092

2

(4)


minus 00848311990911199092minus 0120473119909

2

1

minus 012821199092

2

(5)



0005

01015

02025

03035

04045

05

A B C D E F G H I

Tool

wea

r (m

m)

Specimen



01234567



G-r

atio





4 Conclusion










Acknowledgments


References





















2O3



2O3water























CeramicsJournal of







Biomaterials




Journal of


Journal of





CoatingsJournal of

Advances in








MaterialsJournal of


Nano

materials







A 20 20 0024 0020 0032 0023B 20 40 0049 0041 0056 0045C 20 60 0072 0061 0081 0071D 30 20 0031 0025 0041 0031E 30 40 0065 0053 0073 0063F 30 60 0096 0081 0105 0093G 40 20 0045 0037 0063 0046H 40 40 0096 0079 0112 0095I 40 60 0155 0122 0159 0156







+ 0030331199092+ 0011119909

11199092

(2)






+ 0055641199092minus 0084825119909

11199092

(3)



0002004006008

01012014016018



MRR

(cm

3s)




+ 001111990911199092+ 0007643119909

2

1

+ 000064291199092

2

(4)


minus 00848311990911199092minus 0120473119909

2

1

minus 012821199092

2

(5)



0005

01015

02025

03035

04045

05

A B C D E F G H I

Tool

wea

r (m

m)

Specimen



01234567



G-r

atio





4 Conclusion










Acknowledgments


References





















2O3



2O3water























CeramicsJournal of







Biomaterials




Journal of


Journal of





CoatingsJournal of

Advances in








MaterialsJournal of


Nano

materials




0002004006008

01012014016018



MRR

(cm

3s)




+ 001111990911199092+ 0007643119909

2

1

+ 000064291199092

2

(4)


minus 00848311990911199092minus 0120473119909

2

1

minus 012821199092

2

(5)



0005

01015

02025

03035

04045

05

A B C D E F G H I

Tool

wea

r (m

m)

Specimen



01234567



G-r

atio





4 Conclusion










Acknowledgments


References





















2O3



2O3water























CeramicsJournal of







Biomaterials




Journal of


Journal of





CoatingsJournal of

Advances in








MaterialsJournal of


Nano

materials




4 Conclusion










Acknowledgments


References





















2O3



2O3water























CeramicsJournal of







Biomaterials




Journal of


Journal of





CoatingsJournal of

Advances in








MaterialsJournal of


Nano

materials























CeramicsJournal of







Biomaterials




Journal of


Journal of





CoatingsJournal of

Advances in








MaterialsJournal of


Nano

materials










CeramicsJournal of







Biomaterials




Journal of


Journal of





CoatingsJournal of

Advances in








MaterialsJournal of


Nano

materials



Documents

Research Article Performance of Water-Based Zinc Oxide ...downloads.hindawi.com/journals/jnp/2014/175896.pdf · FacultyofMechanicalEngineering,UniversitiMalaysiaPahang,Pekan,Pahang,Malaysia