Experimental investigation of the effect of single point dressing parameters on grinding of Mo40 hardened steel using mounted point grinding tool

Nowadays, steel hardening has received much attention from researchers due to its frequent use in industries, especially is widely used in energy equipment, aerospace, and petrochemical industries. Low capability in chip removal of hardened steel has always been a significant machining issue. Mounted point grinding is a machining method to improve surface finish and remove burrs on the workpiece walls and hard-to-reach areas. This process is usually used without preparing the grinding wheel before and during the grinding operation, which reduces the proper performance of the process. Environmental contamination, surface integrity, coolant-lubricant-related diseases that affect workers' health, and machining costs heavily depend on the appropriate dressing and proper coolant-lubricant usage. In this study, the effect of dressing conditions (depth of dressing and dressing feed) and the workpiece feed rate during the mounted point grinding of a Mo40 hardened steel in two traditional wet and Minimum Quantity Lubrication (MQL) environments has been investigated. Surface roughness and wheel loading are two significant outputs in every grinding operation. The experimental result of this study reveals an improvement in enhancing the surface roughness in a soft dressing condition. Moreover, this study aimed to achieve proper surface roughness by implementing MQL technique to significantly reduce total cutting fluid usage compared to traditional wet machining. This study observed a higher wheel loading in MQL technique than in the conventional wet grinding.