Experimental evaluation and surface integrity analysis of cryogenic coolants approaches in the cylindrical plunge...

Replacement of pollutant fluids with eco-friendly strategies in machining operations significantly contributes to protecting the environment, diminishing global warming, and ensuring a healthier workplace for employees. This study compares cryogenic coolants with conventional coolants in cylindrical plunge grinding using a Cubic Boron Nitride (CBN) wheel. Samples of 27MnCr5 steel used in the manufacture of automotive transmission components were ground using (i) Liquid Nitrogen (LN₂), (ii) a combination of LN₂ + Minimum Quantity Lubrication (MQL), and (iii) a conventional coolant. The effects of the different cooling methods on the surface integrity of the ground surfaces were examined in terms of surface roughness, microstructural defects, microhardness profiles, and residual stresses. In general, surface roughness was similar for the tested cooling systems, even after grinding three subsequent surfaces in which the process stability was analyzed. Interestingly, the use of eco-friendly cryogenic systems induced fewer microstructural defects than conventional systems, and particularly, LN₂+MQL lead to more compressive surface residual stresses that would improve the in-service performance of components. These results show opportunities for replacing conventional pollutant systems with eco-friendly cryogenic strategies for refrigerating/lubricating grinding processes to reduce harmful effects on the environment and pose health risks to operators.