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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
AN EXPERIMENTAL STUDY OF IMPACT OF
SURFACE GRINDING PARAMETERS ON THE
SURFACE ROUGHNESS
Thesis submitted in accordance with the requirements of the
University Technical Malaysia Melaka (UTeM)
Bachelor of Engineering (Honours) Manufacturing (Process)
By
RUSYDAH BINTI JAMALUDIN
Faculty of Manufacturing Engineering
DECLARATION
I hereby, declared this thesis entitled “An experimental study of surface grinding parameters impact on the surface roughness” is the results of my own research
except as cited in references.
Signature : ……….
Author’s Name : RUSYDAH BINTI JAMALUDIN
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APPROVAL
This PSM submitted to the senate of UTeM and has been as partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Process). The
members of the supervisory committee are as follow:
……… Main supervisor (En Mohd Shahir Kasim)
ABSTRACT
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ABSTRAK
DEDICATION
For my beloved dad, mom, and my brother and my sister.
Especially for my special one.
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ACKNOWLEDGEMENTS
Alhamdulillah, finally I have finished my Final Year Project for the fulfillment of Bachelor of Manufacturing Engineering (Process). First and foremost, I would like to dedicate my deepest gratitude to University Teknikal Malaysia Melaka, especially for Manufacturing Faculty for the provision of funding to carry out this research and my bachelor degree study.
A special thanks to my supervisor, Encik Mohd Shahir Kasim for the supervision along the time I was doing this project. I greatly appreciate his consistent encouragement, advice and invaluable guidance throughout the course of this project.
I wish to extend my special appreciation to Miss Liew Pay Jun for helping me in understanding the result of my studies with her comments and valuable time to complete this project.
I also like to express my thanks to all technician staff at FKP Laboratory that helping me in conducting my experiment especially to Encik Mohd Hisyam Ibrahim, a technician at mesinsyop Lab in guidance me in handling surface grinding machine. Encik Jaafar Lajis, for helping me in material order and guidance me in using facilities in metrology Lab for the experimental analysis process.
Finally, I would like to express my deepest appreciation and gratitude to my
TABLE OF CONTENTS
Declaration………ii Approval………..………iii Abstract………..………...………...iv Abstrak………...v Dedication………vi Acknowledgements………...……..viiTable of Contents………..viii
List of Figures……….xii
List of Tables………..xv
List of Abbreviations, Symbols, Specialized Nomenclature………xvii
List of Appendices………...xviii
1.INTRODUCTION………....1
1.1 Background………...………….1
1.2 Problem Statements………..………...2
1.3 Objectives...……….3
1.4 Scope of Study ………...……….3
1.5 Structure of the reportTopic.………3
1.5.1 Chapter 1: Introduction...………2
1.5.2 Chapter 2: Literature Review ……….4
1.5.3 Chapter 3: Methodology……….4
1.5.4 Chapter 4: Result………4
1.5.5 Chapter 5: Discussion and Analysis………...5
1.5.6 Chapter 6: Conclusion and Recommendation……….5
2. LITERATURE REVIEW………..………8
2.1 Introduction to surface roughness………....8
2.2 Surface structure and properties………...9
2.3 Surface texture ………..10
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2.4.1 Roughness average, Ra………...11
2.4.2 Arithmetic mean, Rz………11
2.4.3. Root mean square, Rq……….12
2.5 Application of surface roughness………..12
2.6 Surface finish measuring method………..14
2.7 Surface grinding parameter………15
2.7.1 Material ………15
2.7.1.1 Carbon steel………..15
………...2.7.1.2 Mild steel………..17
2.7.2 Depth of cut………...19
2.7.3 Feed rate………19
2.8 Surface grinder and accessories……….20
…..2.8.1 The grinding process……….21
….2.8.2 Surface finish……….22
2.8.3 Surface grinding operation……….23
2.9 Design of Experiment (DOE)………23
2.10 Vibration………..25
3.METHODOLOGY………..………..28
3.1 Introduction………..28
...3.2 Design of Experiment (DOE)………28
3.2.1 Stage 1: The objectives of the experiment was defined………...29
3.2.2 Stage 2: The control factors and their level were identified………..29
……3.2.3 Stage 3: Suitable response variables was identified………..30
3.2.4 Stage 4: The appropriate orthogonal array (OA) was selected…………..30
……3.2.5 Stage 5: The experiment was prepared………..31
………….3.2.5.1 Machine preparation ……….31
……….3.2.5.1.1 Machine setup……….32
………….3.2.5.2 Workpiece preparation………...37
3.2.5.3 Experiments procedure and equipments………39
3.2.5.3.1 Machine specification………..39
3.2.5.4 Testing……….50
3.2.5.4.1 Surface roughness……….50
3.2.5.4.2 Data processing flow………52
3.2.5.4.3 Eliminate error………...53
3.2.6 Stage 6: An interpreted result of experiments trials was analyzed……..54
3.2.7 Stage 7: Conclusion and recommendation………...54
3.3 Material testing specification………..55
3.3.1 Spark test………...55
3.3.2 Hardness test………..55
3.4 Project flow chart………57
4. RESULT………..58
4.1 Introduction………58
4.2 Analysis method……….58
4.3 Mild steel analysis………...59
4.3.1 Vibration……….60
4.3.1.1 Vibration versus roughness………...60
4.3.1.2 Feed rate versus vibration………..61
4.3.1.3 Depth of cut versus vibration……… 62
4.3.2 Roughness………64
4.4 Carbon steel analysis………...70
4.4.1 Vibration………71
4.4.1.1 Vibration versus roughness………71
4.4.1.2 Feed rate versus vibration………..72
4.4.1.3 Depth of cut versus vibration………..73
4.4.2 Roughness………..75
4.5 Microscopic surface………81
4.5.1 Mild steel AISI 1020………...81
4.5.2 Carbon steel AISI 1045………..82
5. DICUSSION AND ANALYSIS………...83
5.1 Introduction………..83
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5.3 Surface roughness on mild steel………..………..85
5.4 Surface roughness on carbon steel………..………..85
5.5 Factors affecting the surface roughness………...……….86
5.5.1 Workpiece material………...………...86
5.5.2 Grinding vibration………...……….….86
5.5.3 Grinding wheel wear…..………..87
5.5.4 Coolant……….………...…..88
6. CONCLUSION AND RECOMMENDATION……….89
6.1 Conclusion………89
6.2 Recommendation………...……...90
6.2.1 Investigation with other workpiece………..90
6.2.2 Investigation with ANOVA method……….90
6.2.3 Investigation with other machining parameter………..90
6.2.4 Investigation on other machining characteristics………...91
6.2.5 Improvement in surface grinding performance………..91
6.2.5.1 Improved grinding machines and auxiliary equipment………...91
6.2.5.2 Determine the effect of grinding condition……….91
6.2.5.3 Machine conditions and cost factors………...92
6.2.5.4 Vibration stability………...92
REFERENCES………..93
LIST OF FIGURES
1.1 PSM 1 Gantt Chart 6
1.2 PSM 2 Gantt Chart 7
2.1 Schematic illustration of a cross-section of the surface structure of metals. The thickness of the individual layers depends on both processing conditions and processing environment (Kalpakjian, 2001)
9
2.2 Surface texture (Kalpakjian, 2001) 10
2.3 Standard terminology and symbols to describe surface finish (Kalpajian, 2001)
11
2.4 Coordinates used surface roughness (David, 2002) 12 2.5 Surface measurement in manufacture and performance sequences
(David, 2002)
13
2.6 Elements of a contact stylus profilometer 14
2.7 Carbon steel AISI 1045 15
2.8 Mild Steel AISI 1020 17
2.9 Depth of cut of the workpiece 19
2.10 Cutting actions of abrasive grains 21
2.11 Three stages of chip generation and grinding force components 26
3.1 PSGC-60220 AHR grinding surface machine 31
3.2 A grinding wheel balancing stand 32
3.3 Adjusting counterbalances to balance a grinding wheel 33 3.4 A diamond dresser used to true and dress a grinding wheel 34 3.5 Truing makes the wheel round and true with its axis 34 3.6 Many grinding operation use the flood system to keep the
workpiece cool
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3.7 Horizontal table reverse 36
3.8 Workpiece was placed at a constant place on the horizontal table 36
3.9 Samples of workpieces 37
3.10 AISI 1020 specimens 38
3.11 AISI 1045 specimens 38
3.12 Surface grinding machine 39
3.13 Controller 40
3.14 Grinding wheel 40
3.15 Magnetic table 41
3.16 Pretech cool SYN 3000 Green 41
3.17 Horizontal bandsaw 42
3.18 Cutting the material specimens (carbon steel) 42
3.19 Padestal grinding machine 43
3.20 Digital vibration meter 44
3.21 Taking a reading of vibration during machining 44
3.22 Portable roughness measuring machine 45
3.23 Portable roughness measuring machine accessories 45
3.24 Stylus 45
3.25 Vickers micro hardness tester 46
3.26 Mallet 47
3.27 Specimens arrangement on the magnetic table 47 3.28 Filing the burr on the specimen after cutting 48
3.29 Burr on the specimens after cutting 48
3.30 Oils 49
3.31 Specimens after oiling 49
3.32 Degreaser and cleaner 50
3.33 The specimens need to be cleaning before analysis the roughness 50
3.34 Measuring roughness of the workpieces 51
3.35 Measured the surface by press key “start” on the machine 51
3.36 Data processing flow 52
3.38 AISI 1020 spark test 55
3.39 AISI 1045 spark test 55
3.40 Hardness measurement 56
3.41 Project Flow chart 57
4.1 Graph of vibration versus roughness for mild steel 60 4.2 Graph of feed rate (m/min) versus vibration (RMS) 62 4.3 Graph of depth of cut (µ m) versus vibration (RMS) 63
4.4 Minitab report for mild steel analysis 64
4.5 Data analysis in Minitab 14 65
4.6 Normal probability plot of standardized effects 65 4.7 Pareto chart of the standardized effects 66 4.8 Main effects plot (fitted means) for Ra (µm) 67 4.9 Interaction plot (fitted means) for Ra (µm) 68 4.10 Estimate response surface plot of Ra (µm) vs depth of cut, feed
rate
69
4.11 Graph of vibration (RMS) versus Ra (µ m) 71 4.12 Feed rate (m/min) versus vibration (RMS) 73 4.13 Graph of depth of cut versus vibration (RMS) 74 4.14 Minitab report for carbon steel analysis 75
4.15 Data analysis in Minitab 14 76
4.16 Normal probability plots of the standardized effects 76 4.17 Pareto chart of the standardized effects 77
4.18 Main effect (data means) for Ra (µm) 78
4.19 Interaction plot (data means) for Ra (µm) 79 4.20 Estimate surface plot of Ra (µm) vs depth of cut, feed rate 80 4.21 Surface of mild steel AISI 1020 specimens (0.21 µ m) 81 4.22 Surface of carbon steel AISI 1045 specimen (0.24 µm)) 82 5.1 Types of grinding wheel wear (Marinescu, 2001) 87 5.2 Influence of arrangement and number of cleaning nozzle on
surface quality during surface grinding (Marinescu, 2001)
88
LIST OF TABLES
2.1 Chemical composition carbon steel AISI 1045 properties (Geocities, 2008)
16
2.2 Carbon steel AISI 1045 mechanical properties (Geocities, 2008) 16 2.3 Chemical properties of ANSI 1020 (Geocities, 2008) 18 2.4 Mild steel AISI 1020 mechanical properties (Geocities, 2008) 18 2.5 Fundamental pattern of a 2-level, 3 factor factorial (Del,Vecchio,
1997)
25
3.1 Factors and levels selected for the experiments 29
3.2 Chemical composition of the materials 29
3.3 Experimental layout with response value 30 3.4 Chemical compositions of AISI 1020 and AISI 1045 (Geocities,
2008)
38
3.5 AISI 1020 mechanical properties 38
3.6 AISI 1045 mechanical properties 38
3.7 Digital vibration meter machine information 44 3.8 Portable roughness measuring machine accessories function 46 3.9 Hardness standard of workpiece material (Pertik, 2008) 56 3.10 Hardness test result of workpiece material with load of 100N 56
4.1 Mild steel analysis data 59
4.2 Vibration and roughness results for mild steel specimens 60 4.3 Feed rate (m/min) versus vibration (RMS) 61 4.4 Depth of cut (µ m) versus vibration (RMS) 62
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4.4 Depth of cut (µ m) versus vibration (RMS) 68
4.5 Carbon steel analysis data 70
4.6 Vibration (RMS) versus Ra (µm) 71
LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED
NOMENCLATURE
ANOVA - Analysis of Variance
DOE - Design of Experiment
UTeM - Universiti Teknikal Malaysia Melaka
PSM - Projek Sarjana Muda
ANSI - American National Standard Institute
ISO - International Standard Organization
Ra - Roughness average
AA - Arithmetic average
CLA - Centre line average
Rz - Arithmetic mean
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LIST OF APPENDICES
A
-
Summary of findings from past researchB
-
Surface texture standardC
-
Picture of experiment samplesD
-
Surface roughness graphCHAPTER 1
INTRODUCTION
1.1
Background
Surface roughness has been one the most important quality measures in many mechanical products. As early as in 1984, Tarbekin has brought its significant to our attention (Chang, 2001). The impact of two factors, namely the depth of cut and work piece materials on surface roughness is depicted in (Grover, 1996). For clarify of presentation, the most notable models for estimating the ideal surface roughness in surface grinding are brief next. In gathering a good surface finish, grinding machining used in the production and is an important part of the machine tool trade to improved machine construction has permitted the production of parts to extremely fine tolerances with improved surface finish and accuracy of the finish product (Krar,2006). Because of the dimensional accuracy obtained by grinding, interchangeable manufacture has become commonplace in most industries.
The mechanism behind the formation of surface roughness is very dynamic, complicated, and process dependent; it is very difficult to calculate its value through theoretical analysis (Julie, 2007), so other method like Design of Experiment (DOE) has
been using for the analysis. In many cases, grinding eliminate the need of conventional machining. A new development of abrasives and better machines, the
2
powerful tool currently available to experimenters. DOE helps in design an experiment that will provide the most information with the least amount of work. In order to analyze the data, the fractional factorial design as a method in DOE to study which surface grinding parameters that influence surface roughness of the work piece. The parameters clarify to be studied in this project is work piece materials, depth of cut and feed rate.
1.2
Problems Statements
The importance of surface roughness during grinding machining relationship with the parameters has to be studied in this project. While, the surface also contributed an importance factor in the industry, the surface technology currently becomes importance in the engineering industry because of several factors.
The importance of the manufacturing process is the final link in design through the manufacturing route to reduce costs and improve quality among competition. The study of surface grinding parameters impact that effected surface roughness contributed for further studies in manufacturing process in producing a good surface quality. The important influence of geometry and roughness in tribological problems has been accepted for many years only limited progress has been made in understanding the exact mechanisms involved and incorporating this knowledge into surface finishing processes designed to improve performance. This project presents an approach to surface topography measurement and analysis which allows many of these problems to be examined in a great detail. The influence of surface roughness on contact behavior ia a great tribological situations.
This research study is aimed to find out the answers for the following questions:
i. What are the influence of machining parameters (feed rate and depth of cut) of the surface grinding machine to the surface roughness for mild steel and carbon steel?
1.3
Objectives
The objectives of the project are to:
i. To finds the significant machining parameters (feed rate and depth of cut) that influence machining characteristics through Design of Experiment (DOE).
ii. To analyzed a data from the experiment by using MINITAB 14 software.
