Optimization of Process Parameters in Surface Grinding Using Response Surface Methodology

Abstract

Surface grinding is the most common process used in the manufacturing sector to produce smooth finish on flat surfaces. Surface quality and metal removal rate are the two important performance characteristics to be considered in the grinding process. The main purpose of this work is to study the effects of abrasive tools on EN24 steel surface by using three parameters (Grinding wheel speed, table speed & Depth of cut). This study was conducted by using surface grinding machine. In this work, empirical models were developed for surface roughness and metal removal rate by considering wheel speed, table speed and depth of cut as control factors using response surface methodology. In this Response surface methodology (RSM) was applied to determine the optimum machining parameters leading to minimum surface roughness and maximum metal removal rate in Surface grinding process. Grinding is a finishing process used to improve surface finish, abrade hard materials, and tighten the tolerance on flat and cylindrical surfaces by removing a small amount of material. In grinding, an abrasive material rubs against the metal part and removes tiny pieces of material. Basically grinding is nothing but removal of metal at a much faster rate than was earlier done with single edge tools such as chisels. Apart from being used as material removal process, it is also used to sharpen the cutting edges of cutting tools and sharp objects such as knives, although the underlying process of material removal is the same, but with a different purpose to produce a sharp edge rather than to reduce size. The surface roughness and material removal rate have been identified as quality attributes and are assumed to be directly related to performance of mechanical pieces, productivity and production costs. For these reasons there has been research and development with the objective of optimizing cutting conditions, to obtain a desired machinability. V.S.R.Murthy et.al (1) found the abrasive wear behavior of SiC whisker-reinforced borosilicate and magnesium aluminosilicate (MAS). Composites are investigated under different conditions. Kassim S. Al-Rubaie et.al (2) In this paper the two-body abrasive wear behaviour of aluminium matrix composites reinforced with silicon carbide particles has been investigated. A.Barbacki et.al (3) This paper presents results of investigations concerning the surface layer alterations in hardened steels induced by turning with alumina and CBN edges and grounding with CBN grinders. Xipeng Xu et.al (4) In this paper the present investigation was dedicated to elucidate abrasive-wear mechanisms during surface grinding of a titanium alloy (TC4) and a nickel-based super alloy (K417) by using silicon carbide (SiC), alumina (Al2O3), and cubic boron nitride (CBN) wheels. Anne Venu Gopalet.al (5) In this paper they studied the Efficient grinding of structural ceramics requires judicious selection of operating parameters to maximize removal rate while controlling surface integrity. K.M. Shorowordi et.al (6) studied the tribo-surface characteristics of two aluminium metal matrix composites (Al-MMC) of compositions Al-13 vol%B4C and Al-13vol%SiC sliding against a commercial phenolic brake pad have been investigated under dry conditions. S.Y. Luoa et.al (7) The purpose of this paper is to investigate the effect of the diamond grain size, the wheel rotation speed, the table rotation speed, and the applied pressure in the vertical flat grinding on the surface roughness of silicon wafers using Taguchi orthogonal array design. Jianyi Chen et.al (8) In their research an investigation was undertaken to explore the grinding characteristics and removal mechanisms in high speed grinding of three engineering ceramics- alumina, silicon nitride, and zirconia by using brazed diamond wheels of two different grit sizes. S.A. Kori et.al (9) In the present study, the effect of minor additions of copper (Cu) on the elevated temperature wear behaviour of A356 (Al-7Si-0.3Mg) alloy have been investigated using a high temperature pin-on- disc wear testing machine. M.Janardhan et.al (10) through this paper they want to prove that cylindrical grinding is one of the important metal cutting processes used extensively in the finishing operations. Metal removal rate and surface finish are the important output responses in the production with respect to quantity and quality respectively. Sanjay Agarwal et.al (11) studied the quality of the surface produced during ceramic grinding is important as it influences the performance of the finished part to great extent. K.Kadirgama et.al (12) studied the quality of the surface produced during carbon steel is important as it influences the performance of the finished part to a great extent. This paper discusses the optimization of cylindrical grinding when grinding carbon steel (AISI 1042) and effect of three variables (work speed, diameter of work piece and depth of cut) towards surface roughness with aluminum oxide as grinding wheel. It can be observed from the above review of literatures that the surface roughness and material removal rate is strongly dependent on wheel speed, table speed and depth of cut. Therefore this paper focuses on the effect CNC Grinding parameters on surface roughness and material removal rate are reported using Response surface methodology.