An Experimental Study Of The Impact Of Surface Grinding Parameters On The Surface Roughness.
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
May 2008
ii
3
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
Date
:
28 MARCH 2008
ii
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)
(Official Stamp & Date)
iii
ii
ABSTRACT
Surface roughness and tolerances are the most critical quality measures in many
mechanical products. As competition among industries grows rapidly, customers have
highly demand on quality, making surface roughness become a main competitive demand
in manufacturing industry nowadays. Grinding is one the most popular methods of
machining hard materials. The aim of this researches it to finding the significant
parameter of surface grinding machine that affected surface roughness. There are
parameters such as feed rate, depth of cut that are known to have a large impact on the
surface roughness. This research experiment the specimen using surface grinding
machine which can produce a surface roughness to the specimens. The parameters has
been identified such as material, feed rate (m/min) and depth of cut (µm) to machining
each specimen that running 16 samples for both material of mild steel and carbon steel.
Surface of a mechanical product can created with a number of manufacturing processes.
This research applied Design of Experiment (DOE) approach to studying the effect of
surface grinding parameters on the surface roughness of ground surfaces. Analysis of
variances used to examine the impact of grinding factor and factor interactions on surface
roughness.
iv
ii
ABSTRAK
Kekasaran permukaaan dan ‘tolerance’ adalah ukuran kualiti yang kritikal di dalam
kebanyakan produk mekanikal. Persaingan di dalam industri yang semakin berkembang
maju menyebablan para pengguna mementingkan kualiti menjadikan kekasarasan
permukaaan sebagai permintaaan yang amat tinggi di dalam industri pembuatan pada
masa kini. Mesin pengasah permukaan (surface grinding) adalah antara kaedah yang
popular di dalam permesinan bahan keras. Tujuan kajian ini adalah untuk mencari
parameter yang paling signifikan di dalam mesin pengasah permukaan
(surface
grinding). Di antara parameter yang dikaji adalah kelajuan (feed rate), kedalaman
pemontongan (depth of cut) yang dikenalpasti memberikan impak yang besar terhadap
kekasaran permukaaan. Kajian ini akan menjalankan eksperimen menggunakan mesin
pengasah permukaan (surface grinding) di mana dapat menghasilkan kekasaran
permukaan pada bahan kajian. Parameter yang dikenalpasti adalah seperti jenis material,
kelajuan (feed rate) dan kedalaman pemotongan (depth of cut) untuk permesinan di mana
sebanyak 16 spesimen untuk kedua jenis material; mild steel dan carbon steel. Permukaan
bagi produk mekanikal boleh dihasilkan daripada pelbagai proses pembuatan. Kajian ini
mengaplikasikan kaedah rekabentuk eksperimen untuk mengkaji kesan parameter mesin
pengasah permukaaan (surface grinding) ke atas kekasaran permukaan. Analisis bagi
perbezaan ini digunakan untuk menentukan impak factor mesin dan factor interaksi ke
atas kekasaran permukaaan.
ii
v
DEDICATION
For my beloved dad, mom, and my brother and my sister.
Especially for my special one.
Special thanks for my supervisor.
vi
ii
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
familymembers for their love, sacrifice, motivation and support given during the course
ofthis project. Last but not least, I would like to thank those who have contributed
directly or indirectly toward the success of this project.
vii
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TABLE OF CONTENTS
Declaration……………………………………………………………………………ii
Approval…………………………………………………………..…………………iii
Abstract………..…………………………………………………………...………...iv
Abstrak……………………………………………………………………………......v
Dedication……………………………………………………………………………vi
Acknowledgements…………………………………………………………...……..vii
Table 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
2.4 Surface roughness profile parameters…………………………………………11
viii
ii
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
3.2.5.3.2 Tools and equipments………………………………….43
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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
5.2 Vibration………………………………………………………………………83
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x
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
APPENDICES……………………………………………………………………...96
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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
9
of metals. The thickness of the individual layers depends on both
processing conditions and processing environment (Kalpakjian,
2001)
2.2
Surface texture (Kalpakjian, 2001)
10
2.3
Standard terminology and symbols to describe surface finish
11
(Kalpajian, 2001)
2.4
Coordinates used surface roughness (David, 2002)
12
2.5
Surface measurement in manufacture and performance sequences
13
(David, 2002)
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
36
workpiece cool
xii
ii
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
3.37
Calibrate the precision roughness specimens
53
xiii
ii
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 (µm) 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
69
rate
4.11
Graph of vibration (RMS) versus Ra (µm)
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 µm)
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
88
surface quality during surface grinding (Marinescu, 2001)
5.3
Influence of different type of cooling lubricant on surface quality
xiv
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88
during surface grinding (Marinescu, 2001)
xv
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LIST OF TABLES
2.1
Chemical composition carbon steel AISI 1045 properties
16
(Geocities, 2008)
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,
25
1997)
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,
38
2008)
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 (µm) versus vibration (RMS)
62
4.3
Feed rate (m/min) versus vibration (RMS)
67
xvi
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4.4
Depth of cut (µm) versus vibration (RMS)
68
4.5
Carbon steel analysis data
70
4.6
Vibration (RMS) versus Ra (µm)
71
4.7
Feed rate (m/min) versus vibration (RMS)
72
4.8
Depth of cut (µm) versus vibration (RMS)
73
xvii
ii
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
RMS
-
Root mean square
xviii
ii
LIST OF APPENDICES
A
-
Summary of findings from past research
B
-
Surface texture standard
C
-
Picture of experiment samples
D
-
Surface roughness graph
E
-
Journals of Experimental study of surface grinding
parameters impact on the surface roughness
xix
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CHAPTER 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
rough part is often finished in one grinding operation can reduce need for other
machining. Nowadays, grinding is applied extensively to productions of unhardened
parts where high accuracy and surface finish. Design of Experiments (DOE) is the most
1
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?
ii.
What are the most significant machining parameter that most influences the
surface roughness of mild steel and carbon steel?
2
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.
1.4 Scope of Study
This project will involve experimentation by machining parts using surface grinding
machine in UTeM machine shop. This experimentation will concerned about the
parameters as stated in this project like work piece material, feed and depth of cut.
There are 16 pieces of work piece machining during the experimentation period by
following factorial design of Design of Experiment (DOE) method which the data is
analyzed the same as full factorial or block design. The experiment will be run for 2
samples (mild steel and carbon steel) each machining to get a better data. 8 first of
work piece was analyzed by using portable roughness measuring machine located at
the UTeM metrology lab and then other 8 pieces. This study will analyzed the surface
profile in order to verify the surface grinding parameters impact influence on the
surface roughness.
3
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
May 2008
ii
3
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
Date
:
28 MARCH 2008
ii
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)
(Official Stamp & Date)
iii
ii
ABSTRACT
Surface roughness and tolerances are the most critical quality measures in many
mechanical products. As competition among industries grows rapidly, customers have
highly demand on quality, making surface roughness become a main competitive demand
in manufacturing industry nowadays. Grinding is one the most popular methods of
machining hard materials. The aim of this researches it to finding the significant
parameter of surface grinding machine that affected surface roughness. There are
parameters such as feed rate, depth of cut that are known to have a large impact on the
surface roughness. This research experiment the specimen using surface grinding
machine which can produce a surface roughness to the specimens. The parameters has
been identified such as material, feed rate (m/min) and depth of cut (µm) to machining
each specimen that running 16 samples for both material of mild steel and carbon steel.
Surface of a mechanical product can created with a number of manufacturing processes.
This research applied Design of Experiment (DOE) approach to studying the effect of
surface grinding parameters on the surface roughness of ground surfaces. Analysis of
variances used to examine the impact of grinding factor and factor interactions on surface
roughness.
iv
ii
ABSTRAK
Kekasaran permukaaan dan ‘tolerance’ adalah ukuran kualiti yang kritikal di dalam
kebanyakan produk mekanikal. Persaingan di dalam industri yang semakin berkembang
maju menyebablan para pengguna mementingkan kualiti menjadikan kekasarasan
permukaaan sebagai permintaaan yang amat tinggi di dalam industri pembuatan pada
masa kini. Mesin pengasah permukaan (surface grinding) adalah antara kaedah yang
popular di dalam permesinan bahan keras. Tujuan kajian ini adalah untuk mencari
parameter yang paling signifikan di dalam mesin pengasah permukaan
(surface
grinding). Di antara parameter yang dikaji adalah kelajuan (feed rate), kedalaman
pemontongan (depth of cut) yang dikenalpasti memberikan impak yang besar terhadap
kekasaran permukaaan. Kajian ini akan menjalankan eksperimen menggunakan mesin
pengasah permukaan (surface grinding) di mana dapat menghasilkan kekasaran
permukaan pada bahan kajian. Parameter yang dikenalpasti adalah seperti jenis material,
kelajuan (feed rate) dan kedalaman pemotongan (depth of cut) untuk permesinan di mana
sebanyak 16 spesimen untuk kedua jenis material; mild steel dan carbon steel. Permukaan
bagi produk mekanikal boleh dihasilkan daripada pelbagai proses pembuatan. Kajian ini
mengaplikasikan kaedah rekabentuk eksperimen untuk mengkaji kesan parameter mesin
pengasah permukaaan (surface grinding) ke atas kekasaran permukaan. Analisis bagi
perbezaan ini digunakan untuk menentukan impak factor mesin dan factor interaksi ke
atas kekasaran permukaaan.
ii
v
DEDICATION
For my beloved dad, mom, and my brother and my sister.
Especially for my special one.
Special thanks for my supervisor.
vi
ii
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
familymembers for their love, sacrifice, motivation and support given during the course
ofthis project. Last but not least, I would like to thank those who have contributed
directly or indirectly toward the success of this project.
vii
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TABLE OF CONTENTS
Declaration……………………………………………………………………………ii
Approval…………………………………………………………..…………………iii
Abstract………..…………………………………………………………...………...iv
Abstrak……………………………………………………………………………......v
Dedication……………………………………………………………………………vi
Acknowledgements…………………………………………………………...……..vii
Table 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
2.4 Surface roughness profile parameters…………………………………………11
viii
ii
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
3.2.5.3.2 Tools and equipments………………………………….43
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ii
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
5.2 Vibration………………………………………………………………………83
ii
x
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
APPENDICES……………………………………………………………………...96
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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
9
of metals. The thickness of the individual layers depends on both
processing conditions and processing environment (Kalpakjian,
2001)
2.2
Surface texture (Kalpakjian, 2001)
10
2.3
Standard terminology and symbols to describe surface finish
11
(Kalpajian, 2001)
2.4
Coordinates used surface roughness (David, 2002)
12
2.5
Surface measurement in manufacture and performance sequences
13
(David, 2002)
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
36
workpiece cool
xii
ii
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
3.37
Calibrate the precision roughness specimens
53
xiii
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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 (µm) 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
69
rate
4.11
Graph of vibration (RMS) versus Ra (µm)
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 µm)
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
88
surface quality during surface grinding (Marinescu, 2001)
5.3
Influence of different type of cooling lubricant on surface quality
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88
during surface grinding (Marinescu, 2001)
xv
ii
LIST OF TABLES
2.1
Chemical composition carbon steel AISI 1045 properties
16
(Geocities, 2008)
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,
25
1997)
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,
38
2008)
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 (µm) versus vibration (RMS)
62
4.3
Feed rate (m/min) versus vibration (RMS)
67
xvi
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4.4
Depth of cut (µm) versus vibration (RMS)
68
4.5
Carbon steel analysis data
70
4.6
Vibration (RMS) versus Ra (µm)
71
4.7
Feed rate (m/min) versus vibration (RMS)
72
4.8
Depth of cut (µm) versus vibration (RMS)
73
xvii
ii
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
RMS
-
Root mean square
xviii
ii
LIST OF APPENDICES
A
-
Summary of findings from past research
B
-
Surface texture standard
C
-
Picture of experiment samples
D
-
Surface roughness graph
E
-
Journals of Experimental study of surface grinding
parameters impact on the surface roughness
xix
ii
CHAPTER 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
rough part is often finished in one grinding operation can reduce need for other
machining. Nowadays, grinding is applied extensively to productions of unhardened
parts where high accuracy and surface finish. Design of Experiments (DOE) is the most
1
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?
ii.
What are the most significant machining parameter that most influences the
surface roughness of mild steel and carbon steel?
2
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.
1.4 Scope of Study
This project will involve experimentation by machining parts using surface grinding
machine in UTeM machine shop. This experimentation will concerned about the
parameters as stated in this project like work piece material, feed and depth of cut.
There are 16 pieces of work piece machining during the experimentation period by
following factorial design of Design of Experiment (DOE) method which the data is
analyzed the same as full factorial or block design. The experiment will be run for 2
samples (mild steel and carbon steel) each machining to get a better data. 8 first of
work piece was analyzed by using portable roughness measuring machine located at
the UTeM metrology lab and then other 8 pieces. This study will analyzed the surface
profile in order to verify the surface grinding parameters impact influence on the
surface roughness.
3