Regression Modeling of Surface Roughness in Grinding

2011 ◽  
Vol 271-273 ◽  
pp. 34-39 ◽  
Author(s):  
Ilhan Asiltürk ◽  
Levent Çelik ◽  
Eyüb Canli ◽  
Gürol Önal
Keyword(s):  
Surface Roughness ◽  
Manufacturing Sector ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Important Indicator ◽  
Manufacturing Method ◽  
Grinding Parameters ◽  
Reliable Model ◽  
Art Industry

Grinding is a widely used manufacturing method in state of art industry. By realizing needs of manufacturers, grinding parameters must be carefully selected in order to maintain an optimum point for sustainable process. Surface roughness is generally accepted as an important indicator for grinding parameters. In this study, effects of grinding parameters to surface roughness were experimentally and statistically investigated. A complete factorial experimental flow was designed for three level and three variable. 62 HRC AISI 8620 cementation steel was used in grinding process with 95-96% Al2O3 grinding wheel. Surface roughness values (Ra, Rz) were measured at the end of process by using depth of cut, feed rate and workpiece speed as input parameters. Experimental results were used for modeling surface roughness values with linear, quadric and logarithmic regressions by the help of MINITAB 14 and SPSS 16 software. The best results according to comparison of models considering determination coefficient were achieved with quadric regression model (84.6% for Ra and 89% for Rz). As a result, a reliable model was developed in grinding process which is a highly complex machining operation and depth of cut was determined as the most effective parameter on grinding by variance analysis (ANOVA). Obtained theoretical and practical acquisitions can be used in various areas of manufacturing sector in the future.

Optimization of Surface Roughness in Centreless Grinding Process Based on Taguchi Method

2021 ◽  
pp. 37-47
Author(s):  
Prosun Mandal
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Wheel Speed ◽  
Depth Of Cut ◽  
Grinding Process ◽  
Signal To Noise ◽  
Grinding Parameters ◽  
Medium Level ◽  
Grinding Conditions ◽  
Valve Opening

This chapter aims to optimize centreless grinding conditions using the Taguchi method for minimizing surface roughness. The grinding operation has been performed according to the L9 orthogonal array in a centreless grinding process. The centreless grinding experiments are carried out on the crane-hook pin of C40 steel. The analysis of variance (ANOVA) and computation of signal to noise (S/N) ratio are adopted to determine the influence of grinding parameters (depth of cut [µm], regulating wheel speed [rpm], and coolant valve opening) on surface roughness. The depth of cut (µm) is found to be the most significant among the grinding parameters on the surface roughness. The signal to noise (S/N) ratio was calculated based on smaller the best criteria. The lower level of depth of cut, medium level of regulating wheel speed, and higher-level coolant valve opening is found to be optimal grinding condition according to the mean response and signal to noise (S/N) ratio.

scholarly journals Research on selection of abrasive grain size and cutting parameters when grinding of interrupted surface using aluminum oxide grinding wheel with ceramic binder

2022 ◽  
pp. 93-102
Author(s):  
Do Duc Trung ◽  
Le Dang Ha
Keyword(s):  
Surface Roughness ◽  
Grain Size ◽  
Aluminum Oxide ◽  
Feed Rate ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Testing Sample ◽  
Abrasive Grain ◽  
Ceramic Binder

In this article, a study on intermittent surface grinding using aluminum oxide grinding wheel with ceramic binder is presented. The testing material is 20XH3A steel (GOST standard – Russian Federation). The testing sample has been sawn 6 grooves, with the width of each groove of 10 mm, the grooves are evenly distributed on the circumference of sample. The testing sample resembles a splined shaft. An experimental matrix of nine experiments has been built by Taguchi method, in which abrasive grain size, workpiece speed, feed rate and depth of cut were selected as input variables. At each experiment, surface roughness (Ra) and roundness error (RE) have been measured. Experimental results show that the aluminum oxide and ceramic binder grinding wheels are perfectly suitable for grinding intermittent surface of 20XH3A steel. Data Envelopment Analysis based Ranking (DEAR) method has been used to solve the multi-objective optimization problem. The results also showed that in order to simultaneously ensure minimum surface roughness and RE, abrasive grain size is 80 mesh, workpiece speed is 910 rpm, feed rate is 0.05 mm/rev and depth of cut is 0.01 mm. If evaluating the grinding process through two criteria including surface roughness and RE, depth of cut is the parameter having the greatest effect on the grinding process, followed by the influence of feed rate, workpiece speed, and abrasive grain is the parameter having the least effect on the grinding process. In addition, the effect of each input parameter on each output parameter has also been analyzed, and orientations for further works have also been recommended in this article

scholarly journals Multi-Objective Optimization for Grinding Parameters of 20CrMnTiH Gear with Ceramic Microcrystalline Corundum

Materials ◽  
2019 ◽  
Vol 12 (8) ◽  
pp. 1352 ◽  
Author(s):  
Shengyong Zhang ◽  
Genbao Zhang ◽  
Yan Ran ◽  
Zhichao Wang ◽  
Wen Wang
Keyword(s):  
Surface Roughness ◽  
Practical Significance ◽  
Grinding Wheel ◽  
Linear Regression Method ◽  
Grinding Process ◽  
Low Carbon ◽  
Multi Objective Optimization ◽  
Multi Objective ◽  
Grinding Parameters ◽  
The Impact

(1) The alloy material 20CrMnTiH is widely used in gear manufacturing, but difficult to process, and its quantity (efficiency) and quality (surface quality) are generally negative correlation indicators. As a difficult but realistic problem, it is of important practical significance to explore how to efficiently grind high-precision low-carbon alloy gear workpieces. (2) Firstly, the pixel method was applied to analyze the grinding principles and explore the grinding parameters—the grinding wheel speed and grinding wheel frame moving speed—as well as the feed rate, which impacts the grinding indicators. Secondly, based on the ceramic microcrystalline corundum grinding wheel and the 20CrMnTiH gear workpiece, controlled experiments with 28 groups of grinding parameters were conducted. Moreover, the impact curves of the grinding parameters on the grinding indicators—the grinding efficiency, grinding wheel life, and surface roughness—were obtained by the multiple linear regression method. Finally, the multi-objective optimization method was used to comprehensively optimize the grinding process. (3) Compared with the traditional grinding process, under optimized grinding parameters, the 20CrMnTiH gear workpieces have a lower surface roughness and a longer grinding wheel life, and require a shorter time to achieve grinding accuracy. (4) The grinding experiments showed that the grinding parameters are linearly related to the grinding indicators. The optimization results show that the precision, efficiency, and economy of the 20CrMnTiH gear grinding process have been improved via the comprehensive optimization of the grinding parameters.

scholarly journals Optimization of parameters in cylindrical and surface grinding for improved surface finish

2018 ◽  
Vol 5 (5) ◽  
pp. 171906 ◽  
Author(s):  
Dinesh Kumar Patel ◽  
Deepam Goyal ◽  
B. S. Pabla
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Surface Finish ◽  
Surface Characteristics ◽  
Surface Grinding ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Cylindrical Grinding ◽  
Grinding Parameters ◽  
Wheel Material

Surface integrity has attracted the attention of researchers for improving the functional performance of engineering products. Improvement in surface finish, one of the important parameters in surface integrity, has been attempted by researchers through different processes. Grinding has been widely used for final machining of components requiring smooth surfaces coupled with precise tolerances. Proper selection of grinding wheel material and grade with grinding parameters can result in an improved surface finish and improved surface characteristics. The present work reports the study of the effect of grinding parameters on surface finish of EN8 steel. Experiments were performed on surface grinding and cylindrical grinding for optimization of grinding process parameters for improved surface finish. Grinding wheel speed, depth of cut, table feed, grinding wheel material and table travel speed for surface grinding operation, and work speed for cylindrical grinding operation were taken as the input parameters with four types of grinding wheels (Al 2 O 3 of grades K and L, and white alumina of grades J and K). The surface roughness was taken as an output parameter for experimentation. The grinding wheel material and grade have been observed to be the most significant variables for both cylindrical grinding and surface grinding. Surface roughness in the case of surface grinding is better compared to that of cylindrical grinding, which can be attributed to vibrations produced in the cylindrical grinding attachment. Surface roughness ( R a ) values of 0.757 µm in cylindrical grinding and 0.66 µm in surface grinding have been achieved.

scholarly journals PARAMETRIC ANALYSIS OF A GRINDING PROCESS USING THE ROUGH SETS THEORY

2020 ◽  
Vol 18 (1) ◽  
pp. 091
Author(s):  
Subham Agarwal ◽  
Shruti Sudhakar Dandge ◽  
Shankar Chakraborty
Keyword(s):  
Rough Sets ◽  
Decision Rules ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Rough Sets Theory ◽  
Related Data ◽  
Grinding Parameters ◽  
Sets Theory

With continuous automation of the manufacturing industries and the development of advanced data acquisition systems, a huge volume of manufacturing-related data is now available which can be effectively mined to extract valuable knowledge and unfold the hidden patterns. In this paper, a data mining tool, in the form of the rough sets theory, is applied to a grinding process to investigate the effects of its various input parameters on the responses. Rotational speed of the grinding wheel, depth of cut and type of the cutting fluid are grinding parameters, and average surface roughness, amplitude of vibration and grinding ratio are the responses. The best parametric settings of the grinding parameters are also derived to control the quality characteristics of the ground components. The developed decision rules are quite easy to understand and can truly predict the response values at varying combinations of the considered grinding parameters.

Experimental Study on Surface Finishing Performances in Quick-Point Grinding

2007 ◽  
Vol 24-25 ◽  
pp. 97-102 ◽  
Author(s):  
Shi Chao Xiu ◽  
Chang He Li ◽  
Guang Qi Cai
Keyword(s):  
Surface Roughness ◽  
Feeding Rate ◽  
Point Contact ◽  
Surface Finishing ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Cylindrical Grinding ◽  
Axial Feeding ◽  
Grinding Speed

There are lower grinding force and temperature in quick-point grinding process because of the higher grinding speed and the less depth of cut, especially the point contact between the grinding wheel and the workpiece due to the point grinding angles. Thus it can achieve better surface finishing process in grinding cylindrical surface. Since the point grinding model is different from the conventional cylindrical grinding in theory, the surface roughness is in relation to the point-grinding angles greatly besides the grain granularity, depth of cut, grinding speed and axial feeding rate like the conventional cylindrical grinding process. Based on the theoretical studies on the surface roughness in the process, the surface finishing experiments and measures at the various grinding parameters were performed. The experimental results show that the process parameters, such as point-grinding angles, depth of cut, grinding speed and axial feeding rate, must be controlled reasonably for the higher surface finishing demand in quick-point grinding process.

Evaluation and investigation of grinding process of biomedical polymer (PEEK)

2021 ◽  
pp. 095440892110225
Author(s):  
Mohammad Khoran ◽  
Bahman Azarhoushang ◽  
Hossein Amirabadi
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Speed Ratio ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Cutting Condition ◽  
Grinding Process ◽  
Wheel Topography ◽  
Overlap Ratio

Polyether ether ketone (PEEK) has been widely used in the medical engineering due to its high strength to weight ratio, creep and wear-resistance, and anti-allergically properties. Grinding is generally used to produce PEEK parts with high accuracy and surface quality requirements. In this research, the tool loading and the effect of cryogenic cooling in the grinding of PEEK are studied for the first time. It is shown that the generated heat in the grinding process, which is mainly influenced by the tool micro-topography, process parameter, and coolant lubricant has an important role in the surface integrity of PEEK. Additionally, the influence of specific material removal rate and the dressing speed ratio on the specific grinding energy of PEEK was studied. The input parameters of the grinding process that are investigated in this study include cutting speed (vs), depth of cut (ae), and feed rate (vft). To investigate the grinding wheel topography, the effects of dressing overlap ratio (Ud) and the dressing speed ratio (qd) were also investigated. Grinding force, surface roughness, and loading of the grinding wheel were considered as output parameters. The experiments were designed based on response surface methodology and the optimum cutting condition was obtained based on this method. The depth of cut and the dressing overlap ratio had respectively the maximum and minimum impact on the surface roughness and cutting forces. Additionally, the tool loading was mainly influenced by the cutting speed.

The study on surface grinding process of TI–6AL–4V alloy with resinoid cBN grinding wheel

2020 ◽  
Vol 34 (22n24) ◽  
pp. 2040135
Author(s):  
Phi-Trong Hung ◽  
Hoang-Tien Dung ◽  
Nguyen-Kien Trung ◽  
Truong-Hoanh Son
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Chemical Reactivity ◽  
Surface Grinding ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Wet Grinding ◽  
Ti Alloys ◽  
Cbn Grinding Wheel

The grinding process of Titanium (Ti) alloys is extremely difficult as the cutting temperature is much higher than other machining processes due to the low thermal conductivity, high chemical reactivity, and rapid work hardening during machining of Ti alloys. This research investigates the effect of technology parameters on the surface roughness in the surface grinding of Ti–6Al–4V (Ti64) alloy with resinoid cBN grinding wheel. The experimental results show that the surface roughness is significantly affected by the feed rate, depth of cut (DOC) and cooling condition. Increasing feed rate or DOC all provides the higher surface roughness. The surface roughness obtained in the wet grinding is higher than those of the dry cutting. The scanning electron microscopy (SEM) images of Ti64 surfaces show that the machining surface with fewer defects can be produced with wet grinding process.

Study on Edge Contact Area and Surface Integrity of Workpiece in Point Grinding Process

2009 ◽  
Vol 407-408 ◽  
pp. 577-581
Author(s):  
Shi Chao Xiu ◽  
Zhi Jie Geng ◽  
Guang Qi Cai
Keyword(s):  
Surface Integrity ◽  
Contact Area ◽  
High Speed ◽  
Ground Surface ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Edge Contact ◽  
Cylindrical Grinding ◽  
Theoretic Foundations

During cylindrical grinding process, the geometric configuration and size of the edge contact area between the grinding wheel and workpiece have the heavy effects on the workpiece surface integrity. In consideration of the differences between the point grinding and the conventional high speed cylindrical grinding, the geometric and mathematic models of the edge contact area in point grinding were established. Based on the models, the numerical simulation for the edge contact area was performed. By means of the point grinding experiment, the effect mechanism of the edge contact area on the ground surface integrity was investigated. These will offer the applied theoretic foundations for optimizing the point grinding angles, depth of cut, wheel and workpiece speed, geometrical configuration and size of CBN wheel and some other grinding parameters in point grinding process.

scholarly journals Study on the Effect of Grinding Pressure on Material Removal Behavior Performed on a Self-Designed Passive Grinding Simulator

2021 ◽  
Vol 11 (9) ◽  
pp. 4128
Author(s):  
Peng-Zhan Liu ◽  
Wen-Jun Zou ◽  
Jin Peng ◽  
Xu-Dong Song ◽  
Fu-Ren Xiao
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Service Life ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Temperature ◽  
Grinding Efficiency

Passive grinding is a new rail grinding strategy. In this work, the influence of grinding pressure on the removal behaviors of rail material in passive grinding was investigated by using a self-designed passive grinding simulator. Meanwhile, the surface morphology of the rail and grinding wheel were observed, and the grinding force and temperature were measured during the experiment. Results show that the increase of grinding pressure leads to the rise of rail removal rate, i.e., grinding efficiency, surface roughness, residual stress, grinding force and grinding temperature. Inversely, the enhancement of grinding pressure and grinding force will reduce the grinding ratio, which indicates that service life of grinding wheel decreases. The debris presents dissimilar morphology under different grinding pressure, which reflects the distinction in grinding process. Therefore, for rail passive grinding, the appropriate grinding pressure should be selected to balance the grinding quality and the use of grinding wheel.

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