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Details of Grant 

EPSRC Reference: GR/S82350/01
Title: Optimisation Of Fluid Application In Grinding
Principal Investigator: Morgan, Professor MN
Other Investigators:
Rowe, Professor WB
Researcher Co-Investigators:
Project Partners:
BP Cosworth Racing Ltd Dantec
Holroyd Machine Tools Gears & Landis Lund Wendt Boart (UK) Ltd
Department: General Engineering Research Institute
Organisation: Liverpool John Moores University
Scheme: Standard Research (Pre-FEC)
Starts: 20 September 2004 Ends: 19 September 2007 Value (£): 322,959
EPSRC Research Topic Classifications:
Manufacturing Machine & Plant
EPSRC Industrial Sector Classifications:
No relevance to Underpinning Sectors
Related Grants:
Panel History:  
Summary on Grant Application Form
Grinding fluid plays a vital role in achieving high removal rates and good workpiece quality. There are however, conflicting recommendations for design of fluid application systems and a lack of knowledge concerning principles of fluid delivery into the grinding contact. In consequence, fluid burn-out is common, grinding quality suffers and substantial energy is usually wasted in larger production grinding systems. This is largely because very little supplied flow usefully reaches inside the grinding contact. Industry has consistently requested research on fluid application systems to determine how much flow is needed, what pressures are required and how the fluid should be injected into the grinding contact.This project develops from the recently completed EPSRC/Industry project: GR/M35161, 'Precision Grinding with Vitrified cBN', in which it was demonstrated that a systematic optimisation of fluid delivery and grinding process parameters resulted in very substantial process improvement and large reductions in cost [1]. The project will also support activities in a current EPSRC/Industry project: GR/R68795, 'A New Grinding Regime - Thermal Limitations to Material Removal by Grinding', (HEDG) in which surprising findings have already been made concerning the cooling role of the fluid in high removal-rate processes.The proposed project aims to acquire, formalise and deliver the understanding needed to achieve optimised fluid application. Fundamental interactions between the fluid system and the grinding system will be investigated. The effects of nozzle flowrate, pressure and velocity on useful flowrate and also on grinding performance will be established. Questions relating to the effects of workpiece material, geometry and form, abrasive type, speed and porosity and coolant type will be addressed. Methods to achieve optimised useful flowrate will be determined and strategies for integrating the outcomes into a total grinding technology will be evaluated. A comprehensive experimental and theoretical programme is proposed, supported with industrial evaluations at a partner production facility. Innovative techniques will be employed to determine the nature of complex fluid flows in the entry to the grinding contact region. The results will be conveyed to industry and to the wider academic community and thus contribute to improved process efficiencies; reduced production costs and reduced environmental impact. This is recognised by industry and strong industrial support is given to the project. The work is timely and is necessary to enhance process capability and competitiveness.
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Further Information:  
Organisation Website: http://www.livjm.ac.uk