A Study on Cost Optimization of External Cylindrical Grinding

2020 ◽  
Vol 977 ◽  
pp. 18-26
Author(s):  
Thi Hong Tran ◽  
Xuan Tu Hoang ◽  
Hong Ky Le ◽  
Quoc Tuan Nguyen ◽  
Thanh Tu Nguyen ◽  
...  
Keyword(s):  
Cost Optimization ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Wheel Wear ◽  
Cylindrical Grinding ◽  
Screening Experiments ◽  
Grinding Parameters ◽  
Hourly Rate ◽  
Proposed Model ◽  
External Cylindrical Grinding

Grinding cost is an essential factor in a grinding process. In external cylindrical grinding, there has been an absence of various input grinding process parameters which have significant effects on the grinding cost. This paper presents an optimization of the grinding cost to determine the optimum exchanged grinding wheel diameter based on the seven input grinding parameters consisting of the initial grinding wheel diameter, the grinding wheel width, the wheel life, the radial grinding wheel wear per dress, the total depth of dressing cut, the machine tool hourly rate, and the grinding wheel cost. Combined with the screening experiments, the influence of the grinding parameters on the optimum exchanged grinding wheel diameter for the external cylindrical grinding process was examined. In addition, the effect of the interactions between the input grinding parameters was also evaluated. Finally, the regression equation for computing the optimum exchanged grinding wheel diameter was introduced. Therefore, the proposed model can be further applied for the external grinding process effectively.

Cost Optimization of External Cylindrical Grinding

2013 ◽  
Vol 312 ◽  
pp. 982-989 ◽  
Author(s):  
Vu Ngoc Pi ◽  
Phan Quang The ◽  
Vu Hong Khiem ◽  
Nguyen Ngoc Huong
Keyword(s):  
Cost Optimization ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Overhead Cost ◽  
Cylindrical Grinding ◽  
Optimum Diameter ◽  
Machine Cost ◽  
External Cylindrical Grinding ◽  
Grinding Time ◽  
Cost Components

This paper introduces a study on cost optimization of external cylindrical grinding. The effects of many grinding process parameters such as the initial grinding wheel diameter, the wheel life, the total dressing depth as well as the effect of cost components including the machine cost, the labor including overhead cost, the grinding wheel cost and so forth were taken into account. A model for calculation the optimum exchanged grinding wheel diameter was proposed. With this optimum diameter, a new and effective way of using the grinding wheel was proposed and both the grinding cost and grinding time can be reduced considerably.

Calculation of Effective Ground Depth of Cut by Means of Grinding Process Model

2011 ◽  
Vol 496 ◽  
pp. 7-12 ◽  
Author(s):  
Takazo Yamada ◽  
Michael N. Morgan ◽  
Hwa Soo Lee ◽  
Kohichi Miura
Keyword(s):  
Process Model ◽  
Ground Surface ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Wheel Wear ◽  
Elastic Deformations ◽  
Proposed Model ◽  
Effective Depth ◽  
Grinding Machine

In order to obtain the effective depth of cut on the ground surface, a new grinding process model taking into account thermal expansions of the grinding wheel and the workpiece, elastic deformations of the grinding machine, the grinding wheel and the workpiece and the wheel wear was proposed. Using proposed model, the effective depth of cut was calculated using measured results of the applied depth of cut and the normal grinding force.

scholarly journals Modeling and experimental analysis of wheel-work interface in the cylindrical plunge grinding process

2014 ◽  
Vol 3 (4) ◽  
pp. 484
Author(s):  
Tarik Tawfeek
Keyword(s):  
Contact Stiffness ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Plunge Grinding ◽  
Workpiece Surface ◽  
Roundness Error ◽  
Cylindrical Grinding ◽  
Grinding Processes ◽  
Proposed Model ◽  
Grinding Machine

This paper presents a study of grinding wheel-workpiece interference in external cylindrical plunge grinding processes. This is to study the effect of workpiece surface memory on the workpiece roundness error after grinding. The study has been carried out theoretically on a model simulating cylindrical grinding process. The model takes contact stiffness, grinding wheel and workpiece wear into consideration. The proposed model was sued to predict the normal grinding forces in cylindrical grinding as a function of the previous height and number of waves of the initial profile.The new model has been validated by conducting experiments on a cylindrical grinding machine. Results indicate that the proposed model shows a good agreement with the experimental data obtained.The results of experiments indicate that the proposed modeling method is both feasible and reliable. The results showed that the theoretical model was effective studying the output of cylindrical grinding process. Normal grinding force, vibration level, and roundness error in cylindrical plunge grinding processes are dependent on the workpiece surface memory. Keywords: Plunge Grinding, Modeling, Roundness Error, Surface Memory.

A New Analytical Model of Heat Flux Distribution to Compute Residual Stresses in the Case of External Cylindrical Grinding Process

2012 ◽  
Vol 445 ◽  
pp. 125-130 ◽  
Author(s):  
Haifa Sallem ◽  
Hédi Hamdi
Keyword(s):  
Heat Flux ◽  
Residual Stresses ◽  
Metal Cutting ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Near Surface ◽  
Workpiece Surface ◽  
Cylindrical Grinding ◽  
Cutting Processes ◽  
External Cylindrical Grinding

Grinding process is an energy intensive process in the sense that, it requires a larger amount of energy per unit of volume of material removal compared to other metal cutting processes. In this case, effects on the ground workpiece in terms of induced residual stresses and metallurgical changes due to heat generated play an important role on the lifetime of parts in their mechanism. In order to investigate effects on the workpiece during external cylindrical grinding process, a new analytical approach is firstly developed to model the action of the grinding wheel as a heat flux, which moves along the workpiece surface. The value and the shape of the heat flux entering the workpiece are directly identified. Based on the established model, numerical simulations are performed to predict temperature, cooling and its effects on residual stress distribution in the ground near surface.

Application of a Floating Nozzle to Grinding Process Using an Edge of Grinding Wheel

2008 ◽  
Vol 389-390 ◽  
pp. 326-331 ◽  
Author(s):  
Shinichi Ninomiya ◽  
Fan Qiang ◽  
Toshiharu Shimizu ◽  
Manabu Iwai ◽  
Tetsutaro Uematsu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Good Control ◽  
Surface Grinding ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Cylindrical Grinding ◽  
Edge Wear ◽  
Grinding Machine ◽  
External Cylindrical Grinding ◽  
Basic Experiments

In order to apply the floating nozzle method to an angular grinding on the external cylindrical grinding, basic experiments on V-groove grinding with the wheel edge were performed on the surface-grinding machine. The results showed that the floating nozzle method could maintain a good control of the wheel edge wear, leading to improved surface roughness compared with a conventional nozzle.

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 Grinding of AISI 4340 steel with interrupted cutting by aluminum oxide grinding wheel

2015 ◽  
Vol 68 (2) ◽  
pp. 229-238
Author(s):  
Hamilton Jose de Mello ◽  
Diego Rafael de Mello ◽  
Eduardo Carlos Bianchi ◽  
Paulo Roberto de Aguiar ◽  
Doriana M. D'Addona
Keyword(s):  
Aluminum Oxide ◽  
Rotation Speed ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Wheel Wear ◽  
Machined Surface ◽  
Aisi 4340 Steel ◽  
4340 Steel ◽  
Grinding Machine ◽  
Aisi 4340

AbstractThere has been a great advance in the grinding process by the development of dressing, lubri-refrigeration and other methods. Nevertheless, all of these advances were gained only for continuous cutting; in other words, the ground workpiece profile remains unchanged. Hence, it becomes necessary to study grinding process using intermittent cutting (grooved workpiece – discontinuous cutting), as little or no knowledge and studies have been developed for this purpose, since there is nothing found in formal literature, except for grooved grinding wheels. During the grinding process, heat generated in the cutting zone is extremely high. Therefore, plenty of cutting fluids are essential to cool not only the workpiece but also the grinding wheel, improving the grinding process. In this paper, grinding trials were performed using a conventional aluminum oxide grinding wheel, testing samples made of AISI 4340 steel quenched and tempered with 2, 6, and 12 grooves. The cylindrical plunge grinding was performed by rotating the workpiece on the grinding wheel. This plunge movement was made at three different speeds. From the obtained results, it can be observed that roughness tended to increase for testing sample with the same number of grooves, as rotation speed increased. Roundness error also tended to increase as the speed rotation process got higher for testing the sample with the same number of grooves. Grinding wheel wear enhanced as rotation speed and number of grooves increased. Power consumed by the grinding machine was inversely proportional to the number of grooves. Subsuperficial microhardness had no significant change. Micrographs reveal an optimal machining operation as there was no significant damage on the machined surface.

scholarly journals Simulation Studies on Centrifugal MQL-CCA Method of Applying Coolant during Internal Cylindrical Grinding Process

Materials ◽  
2020 ◽  
Vol 13 (11) ◽  
pp. 2506
Author(s):  
Seweryn Kieraś ◽  
Marek Jakubowski ◽  
Krzysztof Nadolny
Keyword(s):  
Coolant Flow ◽  
Grinding Wheel ◽  
Geometrical Parameters ◽  
Grinding Process ◽  
Simulation Studies ◽  
Cylindrical Grinding ◽  
Supply Line ◽  
Air Gun ◽  
Internal Cylindrical Grinding ◽  
Cooling And Lubrication

This paper describes simulation studies regarding the application of the centrifugal minimum quantity lubrication (MQL) method simultaneously with the delivery of a compressed cooled air (CCA) stream in the internal cylindrical grinding process. The idea of a new hybrid cooling and lubrication method connecting centrifugal (through a grinding wheel) lubrication by MQL with a CCA stream is described. The methodology of computational fluid dynamics (CFD) simulation studies, as well as the results of numerical simulations, are presented in detail. The aim of the simulations was to determine the most favourable geometrical and kinematic parameters of the system in the context of air-oil aerosol and CCA flow, as well as heat exchange. In the simulation, the variables were the grinding arbor geometrical parameters, the angle of CCA supply line outlets, and the grinding wheel and workpiece peripheral speed. As a result of the simulation studies, the most favourable geometrical parameters were designated, determining the orientation of the ends of the two CCA supply line outlets before and after the grinding zone, the number of openings in the drilled-out grinding arbor, and the influence of the grinding speed on the parameters of the coolant flow and temperature of objects in the grinding zone. In addition, the results of simulation tests made it possible to visualise the velocity vectors of the two-phase coolant flow in a complex system of air-oil aerosol delivery centrifugally through an open structure of a very fast rotating porous layer (grinding wheel), with an additional supply of CCA using an external cold air gun (CAG).

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