An Experimental Study Of The Impact Of Surface Grinding Parameter On Flatness.

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

An Experimental Study of the impact of Surface

Grinding Parameter on Flatness.

Thesis submitted in accordance with the partial requirement of the Universiti Teknikal Malaysia Melaka for the

Bachelor of Manufacturing Engineering (Manufacturing Process)

Nik Shamila Bte Nik Shafie.

Faculty of Manufacturing Engineering 24 March 2008

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DECLARATION

I hereby, declared this thesis entitled “PSM Title” is the results of my own research

except as cited in references.

Signature :

UTeM Library (Pind.1/2007)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS TESIS*

JUDUL: An experimental study of surface grinding parameter on flatness. SESI PENGAJIAN : 2007/2008

Saya Nik Shamila Bte Nik Shafie

mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka .

2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk tujuan pengajian sahaja.

3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi.

4. **Sila tandakan (√)

SULIT

TERHAD

TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

(TANDATANGAN PENULIS) Alamat Tetap: Tarikh: _______________________ Disahkan oleh: (TANDATANGAN PENYELIA) Cop Rasmi: Tarikh: _______________________

* Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM). ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.

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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:

………

(Mohd Shahir B Kasim) (24 March 2008) Project Supervisor

Faculty of Manufacturing Engineering Universiti Teknikal Malaysia Melaka

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iii

ABSTRACT

In the present day, manufacturing environments is becoming increasingly important to be able to deliver quality products at the right time to the market at competitive costs. The quality, cost and time to market depend not only on the design and manufacturing but also on the inspection process adopted. Design specifications rely on extensive usage of form tolerances to ensure that the functionality of surfaces and features of the product are maximized. In this study, an experimental was carried out to study the impact of surface grinding parameters on flatness. The effectiveness of surface grinding machine process is evaluated in terms of flatness. A study was carried out on the influence of the depth of cut and feed rate by using two types of material that is mild steel and carbon steel. This has been done by mean of the technique of Design of Experiments (DOE). Some of the noise parameter also had been observed by using a vibration meter to measure the value of vibration that affects the flatness of surfaces. The experimental results reveal that the most significant factor that influences flatness is depth of cut followed by feed rate. Carbon steel produces more surface flatness compare with mild steel.

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ABSTRAK

Pada masa kini, teknologi pembuatan bagi memastikan kualiti produk yang dipasarkan berada pada tahap yang terbaik disamping kos yang kompetitif amatlah penting. Kualiti, kos dan masa pemasaran bukan sahaja bergantung kepada rekabentuk sesuatu produk serta proses pembuatanya tetapi juga proses pemeriksaan kualiti yang diadaptasikan. Didalam kajian ini,eksperimen telah dijalankan bagi mengkaji kesan pembolehubah-pembolehubah seperti kadar masukan dan kedalam potongan terhadap kerataan dengan menggunakan mesin pengikir permukaan. Manakala bahan kerja yang akan digunakan adalah mild steel serta carbon steel. Kajian ini telah megaplikasikan teknik (DOE) dalam menyelesaikan permasalahan yang ingin dikaji. Ujian kerataan pula telah dijalankan dengan menggunakan Coordinate Measuring Machine (CMM) terhadap kedua-dua jenis bahan kerja yang ingin dikaji iaitu mild steel serta carbon steel. Kesan pembolehubah yang mengganggu eksperimen ini iaitu getaran turut dikaji. Setelah menjalankan kajian ini, didapati faktor-faktor pembolehubah yang memberi kesan terhadap kerataan adalah kedalam potongan kemudian diikuti dengan kadar masukan. Dari sudut bahan kerja pula carbon steel memberikan keputusan kerataan yang lebih baik jika dibandingkan dengan mild steel.

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DEDICATION

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ACKNOWLEDGEMENTS

In the Name of Allah almighty and the most Merciful and Blessing

Be upon His Messenger prophet Muhammad s.a.w and his Companions

I would like to take this opportunity to express my utmost gratitude to everybody who had extended their valuable assistance in the process of completing my thesis work.

First and foremost, I would like to express my appreciation to my project supervisors, Mr. Shahir B Kasim, who has always been so kind and patient to guiding, advising and helping me in all the question and problems arose. He is always ready and willing to share all my problems and achievements in every stage of my thesis work. Thank you very much for all he has extended for the timely completion of my thesis work.

On the other hand, I would like to express my sincere gratitude to my second panel PSM and also my examiner, Dr. Rizal and Mr. Wan Hasrulnizam, to all technicians in machine shop and also metrology laboratory. They had been helping me in resolving numerous conceptual problems regarding my thesis and also about a surface grinding machine and also a coordinate measuring machine (CMM)

I would also want to thank my parents and friends for giving me the moral support throughout this busy but memorable period. Last but not least, I want to thank everyone who had granted their helps willingly and patiently.

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vii

Declaration………..ii

Approval………..………iii

Abstract………..………...……….iv

Abstrak………....v

Dedication………vi

Acknowledgements………...……….vii

Table Of Contents……….viii

List Of Figures………xi

List Of Tables………xii

List Of Abbreviations, Symbols, Specialized Nomenclature………xiii

1. INTRODUCTION………...1

1.1Background………...………3

1.2Problem Statements…………..……….4

1.3Objectives of The Project…..……….6

1.4Scopes of Project…………..……….6

1.5Importance of Study………...6

1.6Thesis Organization………6

1.7Gantt Chart……….7

2. LITERATURE REVIEW………11

2.1 Introduction……….……….11

2.2 Flatness………..………...11

2.1.2 Factor effect flat ground surfaces………...……..13

2.2 Grinding………14

2.3 Wheel selection and the grind ability of the material………...17

2.3.1 Cubic Boron Nitride (CBN)………. ...17

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viii

2.5 Vibration………..21

2.5.1 Forced Vibration………..…………21

2.5.2 Regenerative Vibration………...……….21

2.5.3 What is machine vibration?...22

2.5.4 How is the vibration meter mounted………..………..22

2.6 Material of Workpiece………...…………..26

2.6.1 Mild steel………..26

2.6.2 Carbon Steel……….26

2.7 Spark test………..27

2.7.1 Spark test principle………...…………28

2.8 Hardness………...…29

2.8.1 Hardness test………29

2.9 Process parameter……….30

2.9.1 Depth of Cut……….30

2.9.2 Feed Rate………..30

2.10 Design of Experiment (DOE)………..………...31

2.10.1 Full Factorial Design………..………32

2.11 Conclusion of Literature Review………33

2.12 Previous Research………..35

3. METHODOLOGY..………..………..40

3.1 Introduction……….………..…...40

3.2 Project Flow Chart………41

3.3 Explanation of flow chart……….42

3.4 Design of Experiment (DOE) ……...………...42

3.5 Stages 1: Define the objectives of the experiments………..…….…..43

3.6 Stages 2: Identifications of the control factors and their levels………...……43

3.7 Stages 3: Identify suitable response variables………...………..43

3.8 Stages 4: Select the appropriate Orthogonal Array (OA)………...…….44

3.9 Preparation of the experiment………..…………...……….…45

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3.9.2 Material specification test………46

3.9.2.1 Spark test………...47

3.9.2.2 Hardness test……….48.

3.9.3 Machine preparation………...………..…49

3.10 Pilot running……….………..…………..50

3.11 Experimental procedure and equipments………..50

3.11.1 Measurement for feed rate value………..…...50

3.11.2 Machining……….………..51

3.12 Labelling………...52

3.13 Measurement………53

3.13.1 Flatness………...53

3.14 Stages 6: Analyzed and interpreted results of experiments trials……….…55

3.15 Stages 7: Conclusions and recommendations………..55

4 RESULT AND ANALYSIS………….………...……..56

4.1 Introduction………..…………...56 4.2 Result for feed rate………57

4.3 Result for hardness………...58

4.3.1 Result for hardness (carbon steel)……….58

4.3.2 Result for hardness (mild steel)………59

4.4 Findings and Data Analysis of Flatness………...61

4.4.1: The result of average flatness value for mild steel………..61

4.4.2 Normal Probability Plot of Effects for Flatness………..….62

4.4.3: Pareto Chart of the Effects for flatness………....63

4.4.4: Main effects plot for flatness………...64

4.4.5 Mathematical Model Development for Flatness………...…65

4.5 The result of average flatness value for carbon steel………...….66

4.5.1: Normal Probability Plot of Effects for Flatness………..….67

4.5.2 Pareto chart of the effects for Flatness…………...…………..…….68

4.5.3 Main effects plot for flatness………69

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4.6 The result of average vibration value for mild steel……….……71

4.6.1 Main Effects Plot (data means) for vibration………...72

4.6.2 Scatter plot for mild steel (vibration versus flatness)………...73

4.7 The result of average vibration value for carbon steel……….74

4.7.1 Main Effects Plot (data means) for vibration………...75

4.7.2 Scatter plot for carbon steel (vibration versus flatness)………...…76

5.0 DISCUSSION………..…...77

5.1 Introduction………..77

5.2 Discussion on Flatness……….77

5.2.1 Effect of Feed Rate on Flatness………78

5.2.3 Effect of Depth of cut on Flatness………78

5.2.4 Effect of Material on Flatness………...79

5.2.4 Temperature………...………...80

5.2.5 Grinding Wheel………80

5.2.6 Coolant………..…...81

5.2.7 Vibration………...81

5.3 Image analyzer observation of the surfaces……….82

6.0 RECOMMENDATION AND CONCLUSION………...85

6.1 Introduction……….85

6.2 Recommendation……….85

6.2.1 Investigation of other workpiece or Material………...85

6.2.2 Investigation of Other Machining Parameters……….….85

6.2.3 Investigation of Other Machining Characteristics………86

6.3 Conclusion………...87

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LIST OF FIGURES

2.1 Surfaces Flatness. 11

2.2 Symbol for flatness. 12

2.3 Flatness Tolerances. 12

2.4 Flatness of workpiece from control position. 14

2.5 Surface Grinding Machine. 16

2.6 Correct way to mount the vibration meter. 23

2.7 Vibration meter must be firmly attached. 24

2.8 The vibration meter is oriented correctly. 25

2.9 Various common spark patterns for different metals. 27

3.1 Project Flow Chart 40

3.2 Bend saw machine 45

3.3 Filling process. 45

3.4 The workpiece is located in a same location on the surface grinding table.

3.5 Bench grinder 46

3.6 Mild steel sparks. 46

3.7 Carbon steel sparks. 47

3.8 Brinnel test machine. 47

3.9 The vibration meter is magnetized to grinding wheel housing. 51 3.10 The specimen is label by using a sticker and it is number referred to

the DOE table.

3.11 Measurement of flatness by using Coordinate Measuring Machine (CMM)

3.12 A Coordinate Measuring Machine (CMM) 53

4.1 Normal probability plots of effects for flatness. 61

4.2 Pareto chart of the effects for flatness. 62

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xii

4.4 Normal Probability Plot of Effects for Flatness. 66

4.5 Pareto chart of the effects for flatness. 67

4.6 Main effects plot for flatness. 68

4.7 Main Effects Plot (data means) for vibration. 71

4.8 Scatter plot for mild steel (vibration versus flatness) 72

4.9 Main effects Plot (data means) for vibrations. 74

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xiii

LIST OF TABLES

1.7 Gantt Chart 9

2.1 Typical ranges of speed and feeds for abrasives process. 18 2.2 Typical recommendations for grinding wheels for use with various

materials.

2.3 General recommendations for grinding fluids. 20

2.4 Grindings fluid characteristics 21

2.10 Fundamentals pattern of a 2-Level, full factorial design. 33

2.11 Summary of findings from past researches. 34

3.1 Factors and level selected of the experiments. 42

3.2 Experimental layout with response value (for mild steel) 42 3.3 Experimental layout with response value (for carbon steel) 44 3.4 The setting of surface Grinding Machine parameters. 50

4.1 Result for feed rate average. 55

4.2 Feed rate value. 56

4.3 Hardness reading for carbon steel. 57

4.4 Hardness reading for mild steel. 58

4.5 The result of average flatness value for mild steel. 60 4.6 Estimated effects and coefficients for flatness (coded unit) 64

4.7 The result of average flatness for carbon steel. 65

4.8 Estimated effects ad coefficients for flatness. 69

4.9 The result of average vibration value for mild steel. 70 4.10 The result of average vibration value for carbon steel. 73

5.2 Table for flatness and vibration value. 78

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xiv

LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED

NOMENCLATURE

AISI - American International Standard Unit. BHN - Brinnel Hardness Number

CMM - Coordinate Measuring machine. CAD - Computer Aided Drawing. CNC - Computer Numerical Control. DOC - Depth of Cut.

DOE - Design of Experiment.

GD&T - Geometric Dimension and Tolerance. GPA - Gigapascal

HRC - Hardness Rockwell HSS - High Speed Steel. MPa - Megapascal.

Min - minimum

PC - Personal Computer Ra - Roughness Average RMS - Root Mean Squares RPM - Rotation Per Minute. T.I.R - Total indicating reading.

3D - 3 Dimensional.

cm - centimeter mm - millimeter. In - Inch

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CHAPTER

INTRODUCTION

1.1 Introduction

Grinding is an important process that precise parts with smooth and consistent surface finish. It is utilized in the fabrication of many everyday products, such as bearing components and is the final machining set in much of today’s precision component manufacturing. Grinding operations are found in nearly all applications of precision materials production. (Leondes. C, 2001).

Grinding is one of the oldest machining processes. Ancient humans became the first grinding engineers when they discovered one could take two rocks and rub them together in order to form tools and weapons. Grinding engineers now employ the most modern techniques to remove material to form their products. In today’s global market, there is the ever-daunting task to make the machining process more efficient. (Irani et al, 2005)

An abrasive material removal (grinding) is one of the oldest machining technologies employed today, and has been utilized by people in manufacturing of parts since the Stone Age (Malkin, 1989). Various research approaches have been undertaken to help eliminate the problems arises in the metal working industry (Hekman K.A et al, 1997). In 1990, Whitney approaches a force control or power control to minimize the effects of the machine compliance in robotic deburring.

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In the area of surface grinding, research has shown that rotating the part, as well as the grinding wheel or using lapping kinematics (which is a combination of rotation and translation) improves the surface flatness (Matsui et al, 1991). Rotating the part causes the variation of path lengths of a grinding wheel grain to be smaller. This creates a force that has less variation, which results in a flatter surface. Unfortunately, the kinematics of this method does not readily fit with existing machine tool configurations therefore restricting its applicability. (Hekman K.A et al,1998)

In the area of active control, Jenkins found that adjusting the depth of cut to maintain a constant grinding force produced a flatter surface (Jenkins, 1996). This result works well for workpieces that are initially flat, long and slender. However, in most cases, the part/wheel contact geometry is changing, causing the force to change, assuming a constant depth of cut.

Yoo and Dornfeld used a model of grinding force, to analytically plan a vertical feed trajectory to compensate for the compliance (Yoo S. M, 1990). Through numerical simulations, they showed that if their vertical feed rate trajectory was followed, in an open-loop manner, the flatness would be improved. Feedback force control (and power control has been successfully applied to improve flatness in the area of robotic deburring of weld beads and mold finishing (Kurfess T.R, 1992). With this strategy, a grinding model that relates material removal rate to force/power is used to back calculate a force/power trajectory which, when applied, causes the generated workpiece to become flatter. The implementation of these schemes requires the priori knowledge of the workpiece geometry and flatness, which in some industrial applications are uncertain variables.

Review of the research work reveals that much work has been done on various aspects of grinding to produce a flatter surface. In this work, a study focused on the surface grinding machine of mild steel and carbon steel has been carried out. Consequently, an analysis on the influence of feed rate and depth of cut were performed.

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Coordinate Measuring Machine is use to inspect a specimen in order to produce a flatter surfaces. This was done using the technique of design of experiments (DOE).

1.2 Background of problems.

Grinding is an extensively used and important machining operation that has been stated to account for approximately 20 to 25% of all machining costs in the industrialized world (Malkin, 1989). Thus, achieving reductions in cycle time while increasing the resultant product quality are significant concerns for manufacturers as global time while increasing the resultant product quality are significant concerns for manufacturers as global competition increases. To achieve high quality precisions surfaces in a timely manner, it is important to control the grinding process to create smooth and contiguous surfaces, obtain a desired geometry with tolerances and limit or mitigate both surfaces and sub surfaces damage to a ground part and to the grinding wheel.

To accomplish this results velocity, position and force must be controlled during grinding. Velocity control relates to the resulting surface finish, while positional controls determine the geometric accuracy. To limit damage to parts and grinding wheel, current industrial grinding practices is to use slower feed rates reducing productivity. The surface flatness is improved at the lowest material rate, in this case the flatness of workpiece is reduced when both feed rate and depth of cut is decreases.

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Control of the grinding force not only reduces the possibility of damages to the parts, but also affects the surface finish and geometry.

Hence, the author has investigated in detail the flatness produced in surface grinding machine on carbon steel and mild steel.

1.3 Statements of problem

This research study is aimed to find out the answers for the following questions:

(i). What is the influence of machining parameters (feed rate and depth of cut) to the mild steel and carbon steel in order to produce flatter surfaces?

The results of this study provide the opportunity to improve the obtainable tolerance achievable on a machine, or to improve the throughput on a machine by reducing the need for spark out passes. Besides that, adjusting the depth of cut during grinding can be used to enhance the dimensional tolerance without the need of additional spark-out passes. (Keith A.H and Steven Y.L, 1998).

While the surface also contributed an importance factor in the industry, flatness is a form tolerances commonly attached to planar surfaces. For example, flatness is a critical tolerance in the assembly of power train. When the engine cylinder heads is bolted to the engine block, the two mating surfaces must be flat to prevent the distortion of the cylinder heads. Similarly, when the transmission valve body is bolted to the transmission cases, the two mating surfaces must be flat to ensure a tight seal and prevent transmission fluid from leaking.

In the manufacture of precision parts and assemblies, especially where the parts will be required to be connected across a surface area in an air-tight or liquid-tight manner,

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flatness is a critical quality of the manufactured surfaces; such surfaces are usually machined or ground to achieve the required degree of flatness.

According to Beers and Tucker, Poor wringing contact of gage block can cause an erroneous flatness measurement. In manufacturing gage blocks, the gagging faces edges are slightly beveled or rounded to eliminate damaging burrs and sharpness. Allowances should be made for this in flatness measurement by extracting the fringe tips where they drop off sharply at the edges. Allowance varies but 0.002 inch is a reasonable bevel width to allow.

On the ease, efficiency and cost of finishing out tenant spaces, slab flatness/levelness also has a major impact .The construction and installation of door frames, movable partitions, pre-fabricated cabinetry and elevator landings are impacted by the flatness and levelness of the floor slabs. Therefore flatness is important in order to increased inspection throughput, to reduced inspection cycle time, high-accuracy, large table dimensions, and to get a higher overall part quality.

Besides that, the flatness technology currently becomes importance in the engineering industry because of the several factors:-

(i). A realization of the importance of the manufacturing process as the final link in the design through manufacturing route.

(ii). There is a desire by industry to reduce costs and improve quality in the face of international competition.

(iii). There is a growing recognition of the legal implication of product performance.

(iv). Data hitherto assumed accurate have been found to be either unreliable or as insufficient explanation of surface phenomena.

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(v). There are been several catastrophic failures which, when the evidence was analyzed, showed the danger of surface and sub surface material transformation caused by exercise heat generation during manufacture. (vi). Major limitation of flatness

(vii). The requirement for higher power to weight ratios and improved engine performances has lead to development of higher strength steels and the use of thinner sections.

1.4 Objectives

The objectives of these projects are:

(i). To study which parameter mostly affects the flatter surfaces by using a surface grinding machine.

(ii). To compare the ability of mild steel and carbon steel in producing a flatter surfaces.

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7 1.5 Scopes

(i). Implementing the machining process by using surface grinding machine.

(ii). The flatness was measured using a Coordinate Measuring Machine. (iii). The material for the workpiece was mild steel and carbon steel.

(iv). To compare the ability of mild steel and carbon steel in producing a flatter surfaces.

(v). To implement the Design of Experiment (DOE) in the experiment.

1.6 Importance of the study.

This study will help to highlights the effects of machining parameter (feed rate and depth of cut) on flatness by using a mild steel and carbon steel.

1.7Thesis organization

This thesis consists of three chapters:-

Chapter 1

Introduction

I. Introduces of flatness, problem arises in industry which drive to develop this experiment, objective and scope of this project.

Chapter 2

Literature Review

II. Reviews on the literature from journal, books and internet. The area covered including principle for flatness, method in finding a flatness, procedures for grinding a flat surfaces etc.

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8 Chapter 3

Materials and Methods/Methodology

III. Describes methodology to develop the experiment, sample preparing, experiment preparing, machine setup etc.

Chapter 4

Results

IV. This chapter is consisting with two sections. The first section is including the presentation of data and secondly the analysis of data.

Chapter 5

Discussion

V. This provides a general discussion on the results of the study, stressing the significance and implications of the findings of the research project undertaken.

Chapter 6

Summary and Conclusions

VI. This section contains a brief summary of the entire work, including methods, results, major conclusions and recommendations arising from the work.

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9 1.7 Gantt Chart.

Project planning

Major activities involved in Project Sarjana Muda 1.(2007)

Project Activities 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Choose and understand the project

that have been suggested Planning Actual

Get supervisor advise Planning

Actual Collect information and related theory Planning

Actual Draft proposal of project Planning

Actual

Learn use Minitab Planning

Actual

Finish a chapter 1 Planning

Actual

Finish a chapter 2 Planning

Actual

Finish a chapter 3 Planning

Actual

Prepare final report Planning

Actual

PSM 1 Presentation Planning

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Control of the grinding force not only reduces the possibility of damages to the parts, but also affects the surface finish and geometry.

Hence, the author has investigated in detail the flatness produced in surface grinding machine on carbon steel and mild steel.

1.3 Statements of problem

This research study is aimed to find out the answers for the following questions:

(i). What is the influence of machining parameters (feed rate and depth of cut) to the mild steel and carbon steel in order to produce flatter surfaces?

(2)

flatness is a critical quality of the manufactured surfaces; such surfaces are usually machined or ground to achieve the required degree of flatness.

Besides that, the flatness technology currently becomes importance in the engineering industry because of the several factors:-

(i). A realization of the importance of the manufacturing process as the final link in the design through manufacturing route.

(ii). There is a desire by industry to reduce costs and improve quality in the face of international competition.

(iii). There is a growing recognition of the legal implication of product performance.

(iv). Data hitherto assumed accurate have been found to be either unreliable or as insufficient explanation of surface phenomena.

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(vii). The requirement for higher power to weight ratios and improved engine performances has lead to development of higher strength steels and the use of thinner sections.

1.4 Objectives

The objectives of these projects are:

(i). To study which parameter mostly affects the flatter surfaces by using a surface grinding machine.

(ii). To compare the ability of mild steel and carbon steel in producing a flatter surfaces.

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7 1.5 Scopes

(i). Implementing the machining process by using surface grinding machine.

(ii). The flatness was measured using a Coordinate Measuring Machine. (iii). The material for the workpiece was mild steel and carbon steel.

(iv). To compare the ability of mild steel and carbon steel in producing a flatter surfaces.

(v). To implement the Design of Experiment (DOE) in the experiment.

1.6 Importance of the study.

This study will help to highlights the effects of machining parameter (feed rate and depth of cut) on flatness by using a mild steel and carbon steel.

1.7Thesis organization

This thesis consists of three chapters:-

Chapter 1 Introduction

I. Introduces of flatness, problem arises in industry which drive to develop this experiment, objective and scope of this project.

Chapter 2

Literature Review

II. Reviews on the literature from journal, books and internet. The area covered including principle for flatness, method in finding a flatness, procedures for grinding a flat surfaces etc.

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Chapter 3

Materials and Methods/Methodology

III. Describes methodology to develop the experiment, sample preparing, experiment preparing, machine setup etc.

Chapter 4 Results

IV. This chapter is consisting with two sections. The first section is including the presentation of data and secondly the analysis of data.

Chapter 5 Discussion

V. This provides a general discussion on the results of the study, stressing the significance and implications of the findings of the research project undertaken.

Chapter 6

Summary and Conclusions

VI. This section contains a brief summary of the entire work, including methods, results, major conclusions and recommendations arising from the work.

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9 1.7 Gantt Chart.

Project planning

Major activities involved in Project Sarjana Muda 1.(2007)

Project Activities 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Choose and understand the project

that have been suggested Planning Actual

Get supervisor advise Planning

Actual Collect information and related theory Planning

Actual Draft proposal of project Planning

Actual

Learn use Minitab Planning

Actual

Finish a chapter 1 Planning

Actual

Finish a chapter 2 Planning

Actual

Finish a chapter 3 Planning

Actual

Prepare final report Planning

Actual

PSM 1 Presentation Planning

An Experimental Study Of The Impact Of Surface Grinding Parameter On Flatness.

UNIVERSITI TEKNIKAL MALAYSIA MELAKA