A Presentation on A high martrial remove rate can get of automotive crankshaft Research Paper.......

2. Member Name
Tahir Tariq(2010-ME-409)
Faizan Ilyas(2010-ME421)
Ali Hussian(2010-Me-453)

3. A High Material Removal Rate
Grinding Process for the Production
of Automotive Crank Shaft
by
P. Comley,I. Walton , T. Jin, D.J.
Stephenson

4. Abstract
 Application of (HED)Grinding
 Thermal Modeling ( Optimization of the grinding cycle
for an automotive steel and cast iron)
 Surface integrity
 High Speed Of Wheel
 Temperature Of work piece

5. Introduction
 High efficiency deep grinding (HEDG)
(i) Reduces Cycle Time
(ii) Maintains Surface Integrity, form & finish
 Is HEDG suitable for Cylindrical Plunge Grinding for
automotive crack shaft (38MnSiVS6) steel Crankshaft.

6. 

7. Experiment
Two stages of Grinding
1) Laboratory
2) Production Machinery

8. Laboratory
 Sample Material is Steel
 Material Removal Rate (100-2000 mm3/s)
Circular Arc Technique
1) Surface temperature
2) Finished temperature.

9. Novel Temperature Technique
The technique uses a set of split samples with each cross-
section coated with a thin (0.2μm) PVD low melting point film
of bismuth, indium or Zinc.( Graph between melt depth
against temperature)

10. XRD (X-Ray Power Diffraction) &
Barkhausen Noise (BN) Measurements.
 Change in Micro Hardness
 Surface Integrity
 Temperature variation
 Residual stress

11. Production Machinery
 Sample Material(Steel and cast iron Crankshaft )
 Simple shaped grinding wheels were replaced with two
fully profiled left and right hand wheels.
 Laminar flow coolant & electroplated CBN were used.
 Pressure Range (10bar-50bar)
 Continuous Power

13. Results

14. When combined with geometric considerations the model shows
that the proportion of heat flux entering the Work piece initially
climbs to a peak then reduces with increasing Q’w, even though the
total heat flux continues to increase

15. Microstructural Analysis
Speed 200 m/s No change in Micro hardness

16.  The microstructural data, shown in Figure 10,
from regions A, B and C (Figure 9) shows that
below 200mm3 /s. Q’.There is no visible
damage. Whilst at the peak there is no
significant degree of thermal damage some
mechanical deformation is apparent. Above
340 Q'w there is less sign of mechanical
deformation and still no evidence of thermal
damage.

17. Conclusions
 HEDG specific material removal rates as high as
2000 mm3/s can be achieved without thermal damage
to the work piece.
 For steel the thermal trend rises up to a peak in the
region of 300 – 350 mm 3/mm's after which it falls.
 In case of Cast iron the peak becomes stable at the
lower value of
 200 mm3 /mm's.
 The thermal modeling approach was shown to be valid
for cylindrical plunge grinding, correlating well with
both thermal measurement and residual stress data.

18.  There was no catastrophic abrasive grit or wheel failure
as a result of the higher loads associated with the HEDG
regime at Qi's up to 2000mm3/s.
 Improved surface integrity and therefore better
component performance and reliability due to relatively
low work piece temperatures