Cylindrical grinding is one of the most important metal cutting processes used extensively in the Metal finishing operations. Metal removal rate and surface finish are the important output responses in the production with respect to quantity and quality respectively. The objective of this paper is to arrive at the optimal grinding conditions that will maximize metal removal rate when grinding IS 319 brass. Empirical models were developed using design of experiments by Taguchi L9 Orthogonal Array and the adequacy of the developed model is tested with ANOVA.
Effect of process parameters on surface roughness during grinding of hot work...IJMER
The major demands in machining of parts are closely controlling both geometrical accuracy
and dimensional of engineering component made up of difficult to shape material is increasing
continuously. Surface roughness is the important output responses in the production with respect to
quality and quantity respectively. The abrasive machining grinding process is mostly used to attain the
closer tolerances with better surface finish. In this work the AISI H11 hot work steel was used to
investigate the role of different working environments (dry , wet cooling and compressed gas) and
process parameters ( feed rate, depth of cut and wheel speed) on surface roughness. It was observed
that under wet cooling environment, decrease in feed rate, depth of cut and increase in wheel speed
resulted in significant increase in surface quality
Effect of process parameters on material removal rate during grinding of hot ...IJMER
Grinding can be described as a multi-tooth metal cutting operation in which material is
generally removed by shearing and ploughing in the form of micro sized chips by the abrasive grits of
the grinding wheel. This paper presents an important investigation of material removal behaviour during
grinding of hot work steel AISI H11 under different working environments (dry, wet cooling and
compressed gas) and process parameters ( feed rate, depth of cut and wheel speed). During the
experimental investigation, Aluminimum oxide grinding wheel was used to perform cutting action. It was
observed that under compressed gas, increase in depth of cut and decrease in feed rate resulted in
significant increase in material removal rate.
OPTIMIZATION OF TURNING PROCESS PARAMETER IN DRY TURNING OF SAE52100 STEELIAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of SAE52100 steel. Carbide inserts were used for machining of SAE 52100 to study effects of process parameters [Cutting speed (S), Feed (F) and depth of cut (d)]. These models can be effectively used to predict the surface roughness (Ra) & material removal rate of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality
products with increased productivity.
Analysis of process parameters in dry machining of en 31 steel by grey relati...IAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of EN-31 steel.Carbide inserts were used for machining of EN-31 to study effects of process parameters [Cutting speed (S), Feed (F) and depth of cut (d)]. These models can be effectively used to predict the surface roughness (Ra) of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality products with increased productivity.Paper presentswork of an investigation of turning process parameters on EN-31 material, for optimization of surface roughness, material removal rate.The experiment is carried out by considering three controllable input variables namely cutting speed, feed rate, and depth of cut.The design of experiment and optimization of surface roughness is carried out by using Taguchi L9 orthogonal array & Grey Relational analysis.
EXPERIMENTAL ANALYSIS AND MODELLING OF GRINDING AISI D3 STEELijmech
Grinding of hardened steels for the realisation of better surface quality of the workpiece is an essentiality
of high productivity environments. The surface grinding of high carbon high chromium steels like AISI D3
with a production level grinding wheel used in the industry is the driver of the present research article. The
experimentation is done in dry as well as pool cooling conditions to ascertain the better of the two
conditions in providing a better set of cutting forces and surface finish. A mathematical model for
evaluating the forces generated during grinding is evolved and on comparison of the results obtained from
the model with the ones from experimentation is found to be correlating. The usage of production level
vitrified grinding wheel has shown good results in terms of lower forces generated and good surface finish
during surface grinding. The results are optimised and the set of inputs which yield good surface finish and
low forces are given. Dry grinding of AISI D13 yields good surface finish than wet grinding. Surface finish
of 0.14 microns is achievable using dry grinding.
Effect of process parameters on surface roughness during grinding of hot work...IJMER
The major demands in machining of parts are closely controlling both geometrical accuracy
and dimensional of engineering component made up of difficult to shape material is increasing
continuously. Surface roughness is the important output responses in the production with respect to
quality and quantity respectively. The abrasive machining grinding process is mostly used to attain the
closer tolerances with better surface finish. In this work the AISI H11 hot work steel was used to
investigate the role of different working environments (dry , wet cooling and compressed gas) and
process parameters ( feed rate, depth of cut and wheel speed) on surface roughness. It was observed
that under wet cooling environment, decrease in feed rate, depth of cut and increase in wheel speed
resulted in significant increase in surface quality
Effect of process parameters on material removal rate during grinding of hot ...IJMER
Grinding can be described as a multi-tooth metal cutting operation in which material is
generally removed by shearing and ploughing in the form of micro sized chips by the abrasive grits of
the grinding wheel. This paper presents an important investigation of material removal behaviour during
grinding of hot work steel AISI H11 under different working environments (dry, wet cooling and
compressed gas) and process parameters ( feed rate, depth of cut and wheel speed). During the
experimental investigation, Aluminimum oxide grinding wheel was used to perform cutting action. It was
observed that under compressed gas, increase in depth of cut and decrease in feed rate resulted in
significant increase in material removal rate.
OPTIMIZATION OF TURNING PROCESS PARAMETER IN DRY TURNING OF SAE52100 STEELIAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of SAE52100 steel. Carbide inserts were used for machining of SAE 52100 to study effects of process parameters [Cutting speed (S), Feed (F) and depth of cut (d)]. These models can be effectively used to predict the surface roughness (Ra) & material removal rate of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality
products with increased productivity.
Analysis of process parameters in dry machining of en 31 steel by grey relati...IAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of EN-31 steel.Carbide inserts were used for machining of EN-31 to study effects of process parameters [Cutting speed (S), Feed (F) and depth of cut (d)]. These models can be effectively used to predict the surface roughness (Ra) of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality products with increased productivity.Paper presentswork of an investigation of turning process parameters on EN-31 material, for optimization of surface roughness, material removal rate.The experiment is carried out by considering three controllable input variables namely cutting speed, feed rate, and depth of cut.The design of experiment and optimization of surface roughness is carried out by using Taguchi L9 orthogonal array & Grey Relational analysis.
EXPERIMENTAL ANALYSIS AND MODELLING OF GRINDING AISI D3 STEELijmech
Grinding of hardened steels for the realisation of better surface quality of the workpiece is an essentiality
of high productivity environments. The surface grinding of high carbon high chromium steels like AISI D3
with a production level grinding wheel used in the industry is the driver of the present research article. The
experimentation is done in dry as well as pool cooling conditions to ascertain the better of the two
conditions in providing a better set of cutting forces and surface finish. A mathematical model for
evaluating the forces generated during grinding is evolved and on comparison of the results obtained from
the model with the ones from experimentation is found to be correlating. The usage of production level
vitrified grinding wheel has shown good results in terms of lower forces generated and good surface finish
during surface grinding. The results are optimised and the set of inputs which yield good surface finish and
low forces are given. Dry grinding of AISI D13 yields good surface finish than wet grinding. Surface finish
of 0.14 microns is achievable using dry grinding.
Optimization of Roughness Value from Tribological Parameters in Hard Turning ...iosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
Effect of Process Parameters on Micro Hardness of Mild Steel Processed by Sur...IOSR Journals
Surface grinding process can be utilized to create flat shapes at a high production rate and low
cost.. In this investigation, indigenously designed set up were used for evaluating the surface grinding process
was established. An experimental investigation was carried out to study the effect of surface grinding process
parameters i.e. Inlet pressure of coolant, grinding wheel speed, work-piece speed, and nozzle angle on the micro
hardness of the mild steel specimen. In the present study Horizontal spindle and reciprocating table type
surface grinding machine fitted with test rig is used and cutting fluid is applied through the convergent nozzle to
throw the cutting fluids at the cutting zone. In order to evaluate the effect of selected process parameters, one
variable approach has been used in the present study. Plots of various Micro Hardness responses have been
used to determine the relationship between the output response and the input parameters. The value of
microhardness of grinded mild steel work-piece varies from 292.63 to 370.73 HV
Parametric Analysis of Mild Steel Specimens Using Roller Burnishing ProcessIRJESJOURNAL
ABSTRACT:- Burnishing, a cold working process, is a very simple and effective method of improving surface properties, which can easily be carried out using existing machines, such as lathe. With changing trends in manufacturing industry, special attention is given on surface finish along with dimensional accuracy and tight geometrical tolerances. Burnishing comes in mind as one of popular finishing process because it is completely chip-less as compared to other finishing processes such as grinding, honing etc. The purpose of the research was to demonstrate burnishing process on ferrous metals namely mild steel alloy. Parametric analysis was done using speed and feed rate as input parameters and surface roughness & surface micro hardness as response variables. Burnishing was performed using Hindustan machine tools (HMT) power lathe (NH 26 model)
The big challenge of the mass production firms is concentrated for achieving high quality
products with good dimensionability with high productivity, less wear on the cutting insert, less use
of cutting fluid, within less time. This paper present dissertation work of an investigation of turning
process parameters on hard EN 31 material, for optimization of surface roughness, material removal
rate, machining time in wet and minimum quantity lubrication system. The experiment is carried out
by considering four controllable input variables namely cutting speed, feed rate, depth of cut and
insert nose radius in the presence of wet & MQL system. This experiment also present the relation
between chip formations and controllable variables along with chip thickness, chip colors & chip
velocity from which its effect on insert wear, quality of product can be easily found out, because of
chip morphology gives indirectly the effect of it on the insert wear. In this dissertation work
minimum quantity lubrication system is used for reducing the cutting zone temperature properly and
very fastly. Finally comparison is carried out between wet and minimum quantity lubrication system
from which one can easily identify which system is better for higher productivity along with high
surface finish. This work also present the productivity (MRR) concept in production. The design of
experiment and optimization of surface roughness, material removal rate, machining time is carried
out by using response surface methodology (RSM). Central composite design method is used (CCD)
for the total experimental design work and its analysis and also for optimization of turning process
parameter by which wastage of the machining time, power can be avoided.
COMPARISON OF SURFACE ROUGHNESS OF COLDWORK AND HOT WORK TOOL STEELS IN HARD ...ijmech
The hard turning process has been attracting interest in different industrial sectors for finishing operations
of hard materials at its hardened state.Surface roughness is investigated in hard turning of AISI D3 and
AISI H13 steels of same hardness 62HRC. In this paper, an attempt has been made to model and predict
the surface roughness in hard turning of AISI D3 and AISI H13 hardened steels using Response Surface
Methodology (RSM). The combined effects of three machining parameters such as cutting speed, feed rate
and depth of cut are investigated for main performance characteristic that is surface roughness. RSM
based Central Composite Design (CCD) is applied as an experimental design. Al2O3/TiC mixed ceramic
tool with corner radius 0.8 mm is employed to accomplish 20 tests with six center points. The acceptability
of the developed models is checked using Analysis of Variance (ANOVA).The combined effects of cutting
speed; feed rate and depth of cut are investigated using surface plots.
Surface Quality Improvement Using Modified Tool Clamping In Boring OperationsIJRES Journal
Boring operations are challenging owing to limited process performance due to inherent tool overhang and resulting vibrations. The tool vibrations can be suppressed with insertion of suitable damping methodology. The present work adopts a method suitable for machine operators, where in insertion of packing sheets at the boring tool support has been suggested. Insertion of number of layers causes frictional phenomenon to dissipate the exciting energy thereby damping the vibrations. Substantial improvement of surface quality of the internally machined surfaces has been noticed in the experiments
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Effectiveness of multilayer coated tool in turning of aisi 430 f steeleSAT Journals
Abstract This paper presents minimization of surface roughness in dry turning of AISI 430F steel using TiN-TiCN-Al2O3-ZrCN multilayer coated cemented carbide & cryo-treated inserts. Effect of cutting velocity, feed rate, depth of cut & machining duration is studied on the surface roughness. Taguchi’s design of experiment is used to find the optimum factor levels. It is found that the feed rate has much effect in producing lower surface roughness followed by speed. The depth of cut has lesser role on surface roughness. The result of Taguchi method shows that cutting velocity of 250m/min, feed rate of 0.25 mm/rev and depth of cut of 0.3mm should be maintained as optimal parameter settings for both coated and cryo-treated tools. Cryo-treated tools perform better. Keywords: Cryo-treatment, Dry Turning, Surface roughness, Taguchi Method
Need for Vapour-Liquid Equilibrium Data Generation of Systems Involving Green...IJERA Editor
Much has been said and written over the years regarding green chemistry concept and use of green solvents. The green solvents can potentially replace the traditional or classical solvents in order to reduce the environment footprint or their harmful impact on human being and/or environment. Vapour-liquid equilibrium data is indispensable for the design of distillation columns for separation processes which account for a large percentage of total costs in a typical chemical plant. Though extensive approach has been made for the replacement of traditional solvents, but not enough consideration been given for vapour-liquid equilibrium data, required for designing separation processes in case of replacement with green solvents. So this paper aims at encouraging vapour-liquid equilibrium data generation for design of efficient separation for binary systems involving ethereal green solvents such as cyclopentyl methyl ether (CPME) and 2-methyl tetrahydrofuran (2-MeTHF). A brief review and outline of procedure for generating vapour-liquid equilibrium data is presented here.
Burning Behavior of Liquid Fuel DropletsIJERA Editor
Ignition of flammable liquids by hot surfaces is well known to automotive and aviation industries. However, only a limited data regarding hot surface ignition (HSI) of pure and commercial fuels is available in literature. Further, relatively few studies have determined the ignition delay and to our knowledge the combustion lifetime. In the present work, we have generated results from an efficient, reproducible, yet simple experimental setup involving a liquid fuel droplet, a horizontal heated stainless steel plate and quiescent environment. Tests were conducted for diesel, biodiesel and its blends as well as vegetable oils, applied/used as single droplets under variety of conditions to the heated surface. The droplet size range was approximately between 1500 micron to 2000 micron. The objective of this experiment was to determine the minimum temperatures for HSI and also the temperatures where 100% probability of ignition was expected. Further, from this experiment, we were also able to obtain the ignition delay and droplet lifetime. As an extension to this study, a separate droplet combustion model was developed to closely study the general burning behavior of these droplets by generating temperature and species concentration profiles. The droplet mass burning rate was also determined. The results obtained in the present work were in a general agreement with the experimental and modeling observations of other studies.
Optimization of Roughness Value from Tribological Parameters in Hard Turning ...iosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
Effect of Process Parameters on Micro Hardness of Mild Steel Processed by Sur...IOSR Journals
Surface grinding process can be utilized to create flat shapes at a high production rate and low
cost.. In this investigation, indigenously designed set up were used for evaluating the surface grinding process
was established. An experimental investigation was carried out to study the effect of surface grinding process
parameters i.e. Inlet pressure of coolant, grinding wheel speed, work-piece speed, and nozzle angle on the micro
hardness of the mild steel specimen. In the present study Horizontal spindle and reciprocating table type
surface grinding machine fitted with test rig is used and cutting fluid is applied through the convergent nozzle to
throw the cutting fluids at the cutting zone. In order to evaluate the effect of selected process parameters, one
variable approach has been used in the present study. Plots of various Micro Hardness responses have been
used to determine the relationship between the output response and the input parameters. The value of
microhardness of grinded mild steel work-piece varies from 292.63 to 370.73 HV
Parametric Analysis of Mild Steel Specimens Using Roller Burnishing ProcessIRJESJOURNAL
ABSTRACT:- Burnishing, a cold working process, is a very simple and effective method of improving surface properties, which can easily be carried out using existing machines, such as lathe. With changing trends in manufacturing industry, special attention is given on surface finish along with dimensional accuracy and tight geometrical tolerances. Burnishing comes in mind as one of popular finishing process because it is completely chip-less as compared to other finishing processes such as grinding, honing etc. The purpose of the research was to demonstrate burnishing process on ferrous metals namely mild steel alloy. Parametric analysis was done using speed and feed rate as input parameters and surface roughness & surface micro hardness as response variables. Burnishing was performed using Hindustan machine tools (HMT) power lathe (NH 26 model)
The big challenge of the mass production firms is concentrated for achieving high quality
products with good dimensionability with high productivity, less wear on the cutting insert, less use
of cutting fluid, within less time. This paper present dissertation work of an investigation of turning
process parameters on hard EN 31 material, for optimization of surface roughness, material removal
rate, machining time in wet and minimum quantity lubrication system. The experiment is carried out
by considering four controllable input variables namely cutting speed, feed rate, depth of cut and
insert nose radius in the presence of wet & MQL system. This experiment also present the relation
between chip formations and controllable variables along with chip thickness, chip colors & chip
velocity from which its effect on insert wear, quality of product can be easily found out, because of
chip morphology gives indirectly the effect of it on the insert wear. In this dissertation work
minimum quantity lubrication system is used for reducing the cutting zone temperature properly and
very fastly. Finally comparison is carried out between wet and minimum quantity lubrication system
from which one can easily identify which system is better for higher productivity along with high
surface finish. This work also present the productivity (MRR) concept in production. The design of
experiment and optimization of surface roughness, material removal rate, machining time is carried
out by using response surface methodology (RSM). Central composite design method is used (CCD)
for the total experimental design work and its analysis and also for optimization of turning process
parameter by which wastage of the machining time, power can be avoided.
COMPARISON OF SURFACE ROUGHNESS OF COLDWORK AND HOT WORK TOOL STEELS IN HARD ...ijmech
The hard turning process has been attracting interest in different industrial sectors for finishing operations
of hard materials at its hardened state.Surface roughness is investigated in hard turning of AISI D3 and
AISI H13 steels of same hardness 62HRC. In this paper, an attempt has been made to model and predict
the surface roughness in hard turning of AISI D3 and AISI H13 hardened steels using Response Surface
Methodology (RSM). The combined effects of three machining parameters such as cutting speed, feed rate
and depth of cut are investigated for main performance characteristic that is surface roughness. RSM
based Central Composite Design (CCD) is applied as an experimental design. Al2O3/TiC mixed ceramic
tool with corner radius 0.8 mm is employed to accomplish 20 tests with six center points. The acceptability
of the developed models is checked using Analysis of Variance (ANOVA).The combined effects of cutting
speed; feed rate and depth of cut are investigated using surface plots.
Surface Quality Improvement Using Modified Tool Clamping In Boring OperationsIJRES Journal
Boring operations are challenging owing to limited process performance due to inherent tool overhang and resulting vibrations. The tool vibrations can be suppressed with insertion of suitable damping methodology. The present work adopts a method suitable for machine operators, where in insertion of packing sheets at the boring tool support has been suggested. Insertion of number of layers causes frictional phenomenon to dissipate the exciting energy thereby damping the vibrations. Substantial improvement of surface quality of the internally machined surfaces has been noticed in the experiments
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Effectiveness of multilayer coated tool in turning of aisi 430 f steeleSAT Journals
Abstract This paper presents minimization of surface roughness in dry turning of AISI 430F steel using TiN-TiCN-Al2O3-ZrCN multilayer coated cemented carbide & cryo-treated inserts. Effect of cutting velocity, feed rate, depth of cut & machining duration is studied on the surface roughness. Taguchi’s design of experiment is used to find the optimum factor levels. It is found that the feed rate has much effect in producing lower surface roughness followed by speed. The depth of cut has lesser role on surface roughness. The result of Taguchi method shows that cutting velocity of 250m/min, feed rate of 0.25 mm/rev and depth of cut of 0.3mm should be maintained as optimal parameter settings for both coated and cryo-treated tools. Cryo-treated tools perform better. Keywords: Cryo-treatment, Dry Turning, Surface roughness, Taguchi Method
Need for Vapour-Liquid Equilibrium Data Generation of Systems Involving Green...IJERA Editor
Much has been said and written over the years regarding green chemistry concept and use of green solvents. The green solvents can potentially replace the traditional or classical solvents in order to reduce the environment footprint or their harmful impact on human being and/or environment. Vapour-liquid equilibrium data is indispensable for the design of distillation columns for separation processes which account for a large percentage of total costs in a typical chemical plant. Though extensive approach has been made for the replacement of traditional solvents, but not enough consideration been given for vapour-liquid equilibrium data, required for designing separation processes in case of replacement with green solvents. So this paper aims at encouraging vapour-liquid equilibrium data generation for design of efficient separation for binary systems involving ethereal green solvents such as cyclopentyl methyl ether (CPME) and 2-methyl tetrahydrofuran (2-MeTHF). A brief review and outline of procedure for generating vapour-liquid equilibrium data is presented here.
Burning Behavior of Liquid Fuel DropletsIJERA Editor
Ignition of flammable liquids by hot surfaces is well known to automotive and aviation industries. However, only a limited data regarding hot surface ignition (HSI) of pure and commercial fuels is available in literature. Further, relatively few studies have determined the ignition delay and to our knowledge the combustion lifetime. In the present work, we have generated results from an efficient, reproducible, yet simple experimental setup involving a liquid fuel droplet, a horizontal heated stainless steel plate and quiescent environment. Tests were conducted for diesel, biodiesel and its blends as well as vegetable oils, applied/used as single droplets under variety of conditions to the heated surface. The droplet size range was approximately between 1500 micron to 2000 micron. The objective of this experiment was to determine the minimum temperatures for HSI and also the temperatures where 100% probability of ignition was expected. Further, from this experiment, we were also able to obtain the ignition delay and droplet lifetime. As an extension to this study, a separate droplet combustion model was developed to closely study the general burning behavior of these droplets by generating temperature and species concentration profiles. The droplet mass burning rate was also determined. The results obtained in the present work were in a general agreement with the experimental and modeling observations of other studies.
Με αφορμή κάποιες ζωγραφιές σε καμβά σκεφτήκαμε την ιστορία τους. Δεν είναι τυχαίο ότι είχα επιλέξει συγκεκριμένα αντικείμενα στη ζωγραφιά. Έγινε η παραγωγή αφηγηματικών ιστοριών από τουςμαθητές πρώτης τάξης. Κάθε ένα έλεγε μια ιδέα και συνέχιζε το άλλο.Στη συνέχεια αφού διαβάσαμε τις ιστορίες τις εικονογραφήσαμε. Το αποτέλεσμα μας άρεσε πολύ.
ANALYSIS OF PROCESS PARAMETERS IN DRY MACHINING OF EN-31 STEEL by GREY RELATI...IAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of EN-31 steel.Carbide inserts were used for machining of EN-31 to study effects of process parameters [Cutting speed (S), Feed (F) and depth o f cut (d)]. These models can be effectively used to predict the surface roughness (Ra) of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality products with increased productivity.Paper presents work of an investigation of turning process parameters on EN-31 material, for optimization of surface roughness, material removal rate.The experiment is carried out by considering three controllable input variables namely cutting speed, feed rate, and depth of cut.The design of experiment and optimization of surface roughness is carried out by using Taguchi L9 orthogonal array & Grey Relational analysis.
INVESTIGATION AND OPTIMIZATION OF TURNING PROCESS PARAMETER IN WET AND MQL SY...IAEME Publication
The big challenge of the mass production firms is concentrated for achieving high quality products with good dimensionability with high productivity, less wear on the cutting insert, less use
of cutting fluid, within less time. This paper present dissertation work of an investigation of turning process parameters on hard EN 31 material, for optimization of surface roughness, material removal rate, machining time in wet and minimum quantity lubrication system. The experiment is carried out by considering four controllable input variables namely cutting speed, feed rate, depth of cut and insert nose radius in the presence of wet & MQL system
optimization of process parameters for cnc turning using taguchi methods for ...INFOGAIN PUBLICATION
Coated and uncoated tool inserts offers certain degrees of control on the desired rate of tool wear and surface roughness to an extent. This work pursues the quest for realizing the optimal values for the significant process parameters that bears an influence on the response parameters. Experiments were conducted on the samples of EN 24 alloy steel material with the help of PVD coated TiAlN insert and uncoated carbide insert. The experimental runs carried out with proper variation in the levels. Levels are selected with the help of manufacturing catalogue and by pilot experimentation and results are recorded for further analysis. For this study, 9 runs designed using L9 orthogonal array of Taguchi Design of Experiment. Surface roughness was measured using a Mitutoyo surface tester at test lab and material removal rate is calculated by mathematical equation. The data was compiled into Minitab 17 software for analysis. The relationship between the machining parameters and the response variables were analyzed using the Taguchi Method. Optimization of process parameters is carried out by Grey Relational Analysis method (GRA). GRA method is a powerful and most versatile tool which can manipulate the input data as per requirement and comes with results that can be used to have best multi-objective in respective concerns
Experimental Analysis & Optimization of Cylindirical Grinding Process Paramet...IJERA Editor
As per the modern Industrial requirements, higher surface finish mechanical components and mating parts with close limits and tolerances, is one of the most important requirement. Abrasive machining processes are generally the last operations performed on manufactured products for higher surface finishing and for fine or small scale material removal. Higher surface finish and high rate of removal can be obtained if a large number of grains act together. This is accomplished by using bonded abrasives as in grinding wheel or by modern machining processes. In the present study, Taguchi method or Design of experiments has been used to optimize the effect of cylindrical grinding parameters such as wheel speed (rpm), work speed, feed (mm/min.), depth of cut and cutting fluid on the surface roughness of EN15AM steel. Ground surface roughness measurements were carried out by Talysurf surface roughness tester. EN15AM steel has several industrial applications in manufacturing of engine shafts, connecting rods, spindles, studs, bolt, screws etc. The results indicated that grinding wheel speed, work piece speed, table feed rate and depth of cut were the significant factors for the surface roughness and material removal rate. Surface roughness is minimum at 2000 r.p.m. of grinding wheel speed , work piece speed 80 rpm, feed rate 275 mm/min. and 0.06 mm depth of cut.
Optimization of hard part turning of bohler K 110 steel with multiple perform...IAEME Publication
Böhler K110 material is used in High-duty cutting tools, blanking and punching tools& small moulds for the plastics industry where excellent wear resistance is required. It is difficult to machine the material in the hardened state (58 HRc).
A Review on Various Approach for Process Parameter Optimization of Burnishing...ijsrd.com
The aim of this paper is review for different optimization methods used for process parameter optimization of roller burnishing process and Taguchi approach used for process parameter optimization for various processes. The quality of burnishing processed parts are highly depends upon various process parameters of burnishing process. Hence optimization of burnishing process parameters is necessary in order to improve the quality of parts. The purpose of this paper is to explore the reviews for various optimization methods used for process parameter optimization of burnishing process and application of Taguchi approach for design of experiments.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
Automobile Management System Project Report.pdfKamal Acharya
The proposed project is developed to manage the automobile in the automobile dealer company. The main module in this project is login, automobile management, customer management, sales, complaints and reports. The first module is the login. The automobile showroom owner should login to the project for usage. The username and password are verified and if it is correct, next form opens. If the username and password are not correct, it shows the error message.
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Optimization of Metal Removal Rateon Cylindrical Grinding For Is 319 Brass Using Taguchi Method
1. Gaurav Upadhyay et al.Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 5, Issue 6, ( Part -3) June 2015, pp.63-67
www.ijera.com 63|P a g e
Optimization of Metal Removal Rateon Cylindrical Grinding For
Is 319 Brass Using Taguchi Method
*Gaurav Upadhyay, **Ramprasad, ***Kamal Hassan
*(M.Tech Scholar, Dept. of Mechanical Engineering, Lovely Professional University, Phagwara, Punjab, India)
** (M.Tech Scholar, Dept. of Mechanical Engineering, Lovely Professional University, Phagwara, Punjab,
India)
*** (Assistant Prof., Dept. of Mechanical Engineering, Lovely Professional University, Phagwara, Punjab,
India)
ABSTRACT
Cylindrical grinding is one of the most important metal cutting processes used extensively in the Metal finishing
operations. Metal removal rate and surface finish are the important output responses in the production with
respect to quantity and quality respectively. The objective of this paper is to arrive at the optimal grinding
conditions that will maximize metal removal rate when grinding IS 319 brass. Empirical models were developed
using design of experiments by Taguchi L9 Orthogonal Array and the adequacy of the developed model is tested
with ANOVA.
Keywords-Cylindrical Grinding, IS 319 Brass, Metal Removal Rate, Taguchi Analysis, ANOVA, S/N Ratio.
I. INTRODUCTION
Cylindrical grinding is a metal cutting operation
performed by means of abrasive particle rigidly
mounted on rotating wheel. Each of the abrasive
particle act as single point cutting tool and grinding
wheel acts as a multipoint cutting tool.
The grinding process is frequently considered as
one of the most complex and difficult-to-control
manufacturing processes due to its complex,
nonlinear, and stochastic nature. Therefore,
controlling the grinding process for the improvement
of its yield and productivity would often require a
highly sophisticated control framework [1]
. The main
input parameters that influence the output responses,
metal removal rate, surface roughness, and
temperature etc. are (i) Process Parameters: work
speed, depth of cut, feed rate, dressing condition,
etc. (ii) Machine Parameters: static and dynamic
characteristics, spindle system and table system etc.
(iii) Wheel Parameters: abrasives, grain size, grade,
Structure, binder, shape and dimension, etc. (iv)
Work piece Parameters: fracture mode, mechanical
properties and chemical composition, etc[2]
.
II. LITERATURE REVIEW
Choi et al. [1]
established the generalized model
for power, surface roughness, grinding ratio and
surface burning for various steel alloys and alumina
grinding wheels. It was shown that these models can
predict process conditions over a wide range of
grinding conditions.
KirankumarRamakantraoJagtap et al.[2]
investigated
the effect of cutting parameters (depth of cut (Dc),
Work Speed (Nw), Number of Passes (Np) and
Grinding Wheel Speed (Ns)) and the responses
considered are surface roughness (Ra) and material
removal rate (MRR) in cylindrical grinding using
orthogonal array and Taguchi method. In this study,
an optimized set of three input parameter is
estimated for max MRR & min Ra.
Janardhan et al. [3]
proposed that in cylindrical
grinding metal removal rate and surface finish are
the important responses. The Experiments were
conducted on CNC cylindrical grinding machine
using EN8 material (BHN=30-35) and he found that
the feed rate played vital role on responses surface
roughness and metal removal rate than other process
parameters.
Jae-SeobKwak, et al. [4]
analyzed the surface
roughness of the product and grinding power spent
during the process in the external cylindrical
grinding of hardened SCM440 steel using RSM. It
was found that the depth cut is more influential
factor than the traverse speed for the grinding power
and an increase in infeed changes the maximum
height of the surface roughness more than the center
line average height.
Kruszynski et al [5]
states that, the traverse grinding
process is still considered to be an art and in most
cases relies to a great extent on experience of
machine tool operators who have been in the
profession for years. Due to the decreasing number
of such operators a strong need to support them by
the application of supervision systems is observed
that incorporate more intelligence with similar
generalization and adaptation abilities. For this
RESEARCH ARTICLE OPEN ACCESS
2. Gaurav Upadhyay et al.Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 5, Issue 6, ( Part -3) June 2015, pp.63-67
www.ijera.com 64|P a g e
reason, experimental investigations were carried out
on a common cylindrical grinding machine. The
material was 34CrA16C steel, hardened to 50 HRC.
38A80KVBE aluminum oxide grinding wheel of
495 mm diameter was used.
Shaji and Radhakrishnan[6]
presented a study on
Taguchi method to evaluate the process parameters
in surface grinding with graphite as lubricant. The
effect of process parameters such as speed, feed,
infeed and modes of dressing are analyzed.
Stetiu et al [7]
studied that in grinding, wear is an
integral part of the process and a wear rate that is too
slow can easily be more undesirable in its
consequences than a rapid one. The experiments
were performed on an external cylindrical grinding
machine. The cylindrical test work pieces were
made from 0.5% carbon steel rod of hardness 52
HRc. Al2O3 vitrified bonded grinding wheels of
three different hardness’s (Grade J, K & M) were
used having grain size 40 with a medium structure.
It was concluded that the hardness of a grinding
wheel is the most important property affecting the
wear phenomena.
Monici et al [8]
used an appropriate methodology of
“grinding wheels and coolant” combinations to
analyze the quantity of cutting fluid applied in the
process and its consequences. Based on this analysis,
they have investigated a new form of applying
cutting fluid aimed at improving the performance of
the process. The results revealed that, in every
situation, the optimized application of cutting fluid
significantly improved the efficiency of the process,
particularly the combined use of neat oil and CBN
grinding wheel.
Saglam et al. [9]
investigated the effect of cutting
parameters (grinding force, infeed, work speed and
feed rate) on roundness error and surface roughness
in cylindrical grinding using orthogonal array and
Taguchi method. In this study, it is reported that the
roundness is mostly influenced by the cutting speed,
grinding force and depth of cut, whereas surface
roughness is related to feed rate and work speed.
Shih et al [10]
proposed that, increasing the grinding
wheel speed reduces the average chip thickness and
increase the effective hardness of the wheel,
resulting in more efficient work piece material
removal rates when the work piece material is
ceramic or steel. The grinding machine used in this
study was Weldon AGN5 Cylindrical Grinding
Machine. The grinding wheel used was vitreous
bond CBN. He concluded that, during high speed
grinding experiments of both zirconia and M2 steel,
normal and tangential forces tend to lessen as the
grinding wheel speed increases, but the surface
finish is increases.
Brinksmeier[11]
explains that, in addition to coolant
type, composition and filtration, coolant supply
(nozzle position, nozzle geometry, and supplied
flow rate and jet characteristics) can influence
process productivity, work piece quality and tool
wear considerably. For this reason, the development
of coolant system design should be a first priority.
SAE 52100 steel with different hardness values with
various types of coolant combinations, with various
coolant supply strategies, and with various grades
(Aluminium oxide and CBN) of grinding wheels
have been used to optimize the cooling and
lubrication process in grinding operation. It was
concluded that coolant types, composition, nozzle
design and flow rate can influence process
productivity, work piece quality and tool wear
considerably.
Nathan et al [12]
proposed that, in the grinding
process, a proper estimate of the life of the grinding
wheel is very useful. When this life expires,
redressing is necessary. Hardened C60 steel (Rc 40)
specimens were ground with an A463–K5–V10
wheel in a cylindrical grinding machine. The results
revealed that the surface quality and in-service
behavior of a ground component is affected
seriously by the occurrence of grinding burn. Hence,
techniques for the prediction of the burn threshold
are of great importance. Spark temperature can be
considered to be a good representative of the
grinding zone temperature.
Comley et al [13]
explains that, high efficiency deep
grinding (HEDG) with its high material removal rate
helps to improve cycle times while maintaining
surface integrity, form and finish requirements.
Thermal modeling is used to optimize the grinding
cycle for an automotive steel and cast iron. He
finally demonstrated that the concept of HEDG was
valid for cylindrical plunge grinding using the
selected steel and cast iron materials, and there was
no abrasive grit or wheel failure as a result of the
higher loads associated with the HEDG system at
MRR up to 2000mm3/mm/s.
Hecker et al [14]
explains that, the quality of the
surface generated by grinding determines many
work piece characteristics such as the minimum
tolerances, the lubrication effectiveness and the
component life, among others. A series of
experiments were performed on cylindrical grinding.
The material used was hardened steel 52100 (62
HRc) with an aluminum oxide grinding wheel. He
found that, the predicted surface roughness shows a
good agreement with experimental data obtained
from different kinematic conditions in cylindrical
grinding.
3. Gaurav Upadhyay et al.Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 5, Issue 6, ( Part -3) June 2015, pp.63-67
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Table 1: Chemical Composition of IS 319 Brass
III. EXPERIMENTAL SET-UP AND
DESIGN OF EXPERIMENT
For present work, IS 319 Brass has been
selected as work material. The chemical composition
of IS 319 brass is shown in Table 1.The diameter
and length of these 09 workpieces were 35mm and
75mm respectively. The tests were carried out on
High Precision Cylindrical Grinding Machine with
vitrified Al2O3 grinding wheel (300mm X 127mm X
40mm). Water miscible coolant with 5%
concentration was supplied in all grinding
experiments. The input parameters are depth of cut
(Dc), Work Speed (Nw), and Grinding Wheel Speed
(Ns), and the response considered was metal
removal rate (MRR).The MRR is calculated by
taking the difference between weights of work
materials before and after grinding and it is divided
by the machining time.Process variables and their
levels have been shown in Table 2, whereas the
design of experiment based on Taguchi’s L9
Orthogonal Array method is shown in Table 3. The
obtained values of responses are then compared with
predicted values of regression equations. Minitab 17
version statistical software is used to generate
regression equations and for analysis of obtained
data Taguchi Method is used.
Table 2: Process variables and their levels for
cylindrical grinding process using IS 319 Brass
Level
Depth
of cut
(Dc)µm
Work
speed
(Nw)rpm
Grinding
wheel
speed
(Ns)rpm
Remar
k
1 200 40 11000 Low
2 400 60 17600
Mediu
m
3 600 80 2500 High
Table 3: Design of Experiment for Grinding of IS
319 Brass
Run Dc
(µm)
Nw
(rpm)
Ns
(rpm)
MRR(gm/s)
01 200 40 11000 0.260
02 200 60 17600 0.202
03 200 80 25600 0.196
04 400 40 17600 0.303
05 400 60 25600 0.275
06 400 80 11000 0.311
07 600 40 25600 0.325
08 600 60 11000 0.323
09 600 80 17600 0.314
Table 4: Estimated Model Coefficients for S/N
ratios (Metal Removal Rate)
Term Coef SE
Coef
T P
Constant -11.235 0.132 -84.83 0.000
Dc 200µm -2.014 0.187 -10.75 0.009
Dc 400µm 0.659 0.187 3.52 0.072
Nw 40rpm 0.624 0.187 3.33 0.080
Nw 60rpm -0.405 0.187 -2.16 0.163
Ns
11000rpm
0.682 0.187 3.64 0.068
Ns
17600rpm
-0.207 0.187 -1.10 0.385
IV. RESULTS AND DISCUSSIONS
Table 6 and Figure 1 depict the factor effect on
metal removal rate. The higher the signal to noise
ratio, the more favorable is the effect of the input
variable on the output. The graph shows that, the
optimum value levels for best metal removal rate
(maximum) are at a depth of cut 200 μm, work
speed 40 rpm, and grinding wheel speed of 11000
rpm.
It can be seen that the most influencing parameter to
metal removal rate for IS 319 Brass is depth of cut
(Dc) in µm,followed by Grinding wheel speed and
work speed.
S = 0.397337 R-Sq = 98.64% R-Sq (adj) = 94.58%
IS 319
Designation Cu Pb Fe Zn
IS 319 Brass 58.37 2.85 0.36 38.42
4. Gaurav Upadhyay et al.Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 5, Issue 6, ( Part -3) June 2015, pp.63-67
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Table 5: Analysis of Variance for S/N ratios (Metal
Removal Rate)
Sourc
e
DF Adj SS Adj
MS
F
Value
P
Value
Dc 2 18.984 9.492 60.12 0.016
Nw 2 1.804 0.902 5.71 0.149
Ns 2 2.198 1.099 6.96 0.126
Error 2 .315 0.157
Total 8 23.302
Table 6: Response Table for Signal to Noise Ratios –
Larger is better (Metal Removal Rate)
Level Depth of
Cut(μm)
Work
Speed(rpm)
Grinding
Wheel
Speed
(rpm)
1 -13.249 -10.611** -10.554**
2 -10.576 -11.641 -11.442
3 -9.880** -11.454 -11.710
Delta 3.370 1.029 1.156
Rank 1 3 2
**indicates higher S/N Ratio
Fig 1: Main Effect Plot of S/N ratios for Metal
Removal Rate
Fig 2: Interaction Plot for S/N Ratios of Metal
Removal Rate
For validation, the predicted values obtained by
regression equation for Metal Removal Rate are
compared with the experimental values.
Also, the optimum set of parameters obtained from
analysis is shown in Table 7.
Regression Equation for Metal Removal Rate for
grinding of IS 319 Brass
MRR=0.27878-
0.05944Dc200+0.01756Dc400+0.04189Dc600+0.0
1722Nw40-0.01211Nw60
0.00511Nw80+0.01922Ns11000-0.00578Ns17600-
0.01344Ns25600
Table 7: Optimum Set of Parameters
Optimal Set
For
Controlled
Factors
Optimum Set
Metal Removal
Rate
(MRR in gm/s)
Dc (µm) 200
Nw (rpm) 40
Ns (rpm) 11000
V. CONCLUSIONS
For Metal Remove (MRR), the depth of cut (µm)
was the most influencing factor for IS 319 Brass
work material followed by grinding wheel speed and
work speed.
So, to achieve the maximum metal removal rateof IS
319 Brass, employ depth of cut of 200μm, work
speed of 40 rpm and grinding wheel speed of 11000
rpm.
5. Gaurav Upadhyay et al.Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 5, Issue 6, ( Part -3) June 2015, pp.63-67
www.ijera.com 67|P a g e
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[13] P. Comley, I. Walton2, T. Jin, D.J.
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