Grinding is an abrasive machining process used for the final shaping of components that require very smooth surfaces and a high dimensional accuracy. In recent years, the costs of industrial grinding operations have increased with a greater demand for high-strength, low-weight superalloy components. Titanium and nickel-based alloys are desirable for their high creep-rupture strength and corrosion and oxidation resistance in high-temperature environments. However, they are very difficult to grinding due to a combination of poor thermal properties, rapid work-hardening, and a high level of chemical reactivity. In this thesis, two methods are investigated to improve process performance in plunge centerless grinding of Inconel 718 and Ti-6Al-4V superalloy fasteners: (i) economic optimization of grinding process parameters and (ii) reduced quantity lubrication using a graphite nanoplatelet-enhanced grinding fluid. In the first part, a systematic methodology is presented for finding the optimum parameters in two stages: (i) modeling of process and part quality constraints, and (ii) determination of optimum grinding conditions in the feasible operating region. In the second part, the performance of a graphite nanoplatelet-enhanced grinding fluid in reduced quantity lubrication centerless grinding is evaluated to assess its potential as a cost-effective alternative to the traditional flood cooling method. The results of the study indicate that an appreciable reduction in the cost of the superalloy grinding operation can be achieved by operating at the optimum parameters. In addition, it is shown that the application of a graphite-enhanced fluid at a reduced flow rate is more effective than high-volume flood cooling in reducing specific grinding energy levels and wheel wear rates, thus offering the potential to increase process productivity.

A busca das empresas por uma solidez no mercado de trabalho competitivo desempenha um papel relevante na modernização dos processos produtivos, bem como no manuseio adequado das técnicas de cada processo. O processo de retificação centerless de passagem é bastante utilizado nas indústrias, principalmente para produção de grandes lotes de peças cilíndricas, que requerem tolerâncias dimensionais pequenas e superfícies com alto grau de acabamento. As retificadoras centerless são consideradas máquinas complexas devido ao grande número de fatores e parâmetros que influenciam a qualidade do produto e a estabilidade do processo. Mesmo com o avanço tecnológico, na prática industrial, na maioria das vezes, o processo de retificação centerless é determinado de modo empírico. Dentro desta situação é notável a escassez de livrostextos acerca do assunto, principalmente no tocante à definição de parâmetros de ajustagem de máquina. Este cenário tem intensificado a busca por soluções através de estudos sobre processos de retificação centerless. Nesse contexto, o presente trabalho tem como propósito estudar as correlações dos parâmetros envolvidos no processo de retificação centerless de passagem e a sua influência na qualidade final do produto, assim como, a elaboração de um software para determinar os parâmetros de usinagem necessários para ajuste desse tipo de máquina. Os ensaios realizados permitiram verificar a influência do ângulo de topo da régua de apoio, do ângulo de tangência e a freqüência natural da máquina na circularidade da peça. Analisando-se os resultados constataram-se os melhores ângulos de topo da régua de apoio e os ângulos de tangência para obter os menores valores do erro de circularidade. Verificou-se que é possível evitar peça no formato de uma oscilação harmônica, conhecendo-se a freqüência da peça e freqüência natural da máquina. / The search of the companies for a solid and competitive market, does with that they play an important part in the productive processes modernization, as well as in the correct handling of the techniques of each process. Now the Throught-Feed Centerless Grinding process is quite used in the industries, mainly for production of great lots of cylindrical pieces, that request tight dimensional tolerances and surfaces with high degree of finish. The Centerless Grinding are considered complex machines, due to the great number of factors and parameters that influence the product quality and the process stability. Even with the technological progress, in the industrial practices, the machining parameters for grinding are certain empirically and the Centerless Grinding machines adjusted and operated taking into account the "filling" of each operator. In this situation is notable the shortage of books-texts concerning the subject, mainly regarding machine parameters setup. Therefore, the incessant search of solutions exists through studies of Centerless Grinding processes. In this context the present work has as purpose to study the correlation between the parameter of the Throught-Feed Centerless Grinding process and the influence in workpiece accuracy, again software elaboration to determine all necessary machining parameters for adjustment of the Throught-Feed Centerless Grinding. The experimental studies were conducted permited to verify the influence of the work rest blande angle, the workpiece height and the machine frequency in the workpiece roundness error. The results showed what the most work rest blande angle and tangent angle for obtain the smaller workpiece roundness error. In relation to the machine requency, it has been verified workpiece roundness form when the workpiece frequency is same the machine frequency.