Analysis The Contribution And Effect Of Coolant To Straightness In Cylindrical Grinding.
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
ANALYSIS THE CONTRIBUTION AND EFFECT OF COOLANT
TO STRAIGHTNESS IN CYLINDRICAL GRINDING
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Process) with Honours.
by
HAIDZER ISA BIN A RAHMAN
FACULTY OF MANUFACTURING ENGINEERING
2009
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PSM
TAJUK:
“ ANALYSIS THE CONTRIBUTION AND EFFECT OF COOLANT TO STRAIGHTNESS IN
CYLINDRICAL GRINDING
”
SESI PENGAJIAN:
2 008/ 20 09 Semest er 2
Saya HAIDZER ISA BIN A RAHMAN
mengaku membenarkan laporan PSM ini disimpan di Perpust akaan Universit i Teknikal
Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :
1.
2.
3.
4.
Laporan PSM / t esis adalah hak milik Universit i Teknikal Malaysia Melaka dan
penulis.
Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan
unt uk t uj uan pengaj ian sahaj a dengan izin penulis.
Perpust akaan dibenarkan membuat salinan laporan PSM / t esis ini sebagai bahan
pert ukaran ant ara inst it usi pengaj ian t inggi.
*Sila t andakan ( √)
⁄
SULIT
(Mengandungi makl umat yang berdarj ah kesel amat an at au
kepent i ngan Mal aysia yang t er makt ub di dal am AKTA RAHSIA RASMI
1972)
TERHAD
(Mengandungi makl umat TERHAD yang t el ah dit ent ukan ol eh
organisasi / badan di mana penyel idikan dij al ankan)
TIDAK TERHAD
SU26 JALAN HJ HARON
BT 16 ½ KG SOLOK DUKU
78300 MASJID TANAH
MELAKA
Tarikh: _______________________
Cop Rasmi:
Tarikh: _______________________
* Jika laporan PSM i ni SULIT at au TERHAD, sila lampirkan surat daripada pihak organisasi berkenaan
dengan menyat akan sekali sebab dan t empoh t esi s ini perl u dikelaskan sebagai SULIT at au TERHAD.
DECLARATION
I hereby, declared this report entitled “Analysis The Contribution And Effect Of
Coolant To Surface Roughness In Cylindrical Grinding” is the result of my own
research except as cited in references.
Signature
:
………………………………………………..
Author’s Name
:
………………………………………………..
Date
:
……………..…………………………………
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a
partial fulfillment of the requirements for the degree of Bachelor of Manufacturing
Engineering (Manufacturing Process) with Honours. The member of the supervisory
committee is as follow:
(Signature of Supervisor)
………………………………………
(Official Stamp of Supervisor)
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a
partial fulfillment of the requirements for the degree of Bachelor of Manufacturing
Engineering (Manufacturing Process) with Honours. The members of the supervisory
committee are as follow:
(Signature of Principle Supervisor)
………………………………….
(Official Stamp of Principle Supervisor)
(Signature of Co-Supervisor)
………………………………
(Official Stamp of Co-Supervisor)
ABSTRACT
Every fourth year degree students of Universiti Teknikal Malaysia Melaka or known as
UTeM is compulsory to do Bachelor Degree Project (PSM). This is to improve
acknowledgments and skill in solve academic research problem with scientific,
systematic and born as a dedication and competence professional for full fill Program
Outcome (PO) and Program Educational Objective that fixed by FKP. The main point of
this project is to test the effectiveness of three type of coolant concentration with
appropriate to the machining operation by using Universal Cylindrical Grinder Model
OD820S in order to study the machine performance in term of straightness factor. The
objective of this project is to expose student to the important of coolant concentration use
in machining process. These projects are also including machine operating training
session in order to make student easily understand the machine principle to produce full
report writing, slide presentation and report during this project. The studies also concern
the student capability through process and maintenance. All data will be evaluated done
from the project lab result. The contribution of coolant will related to the straightness
and tested with Mahr Formtester MMQ44, after getting the result, conclusion will be able
to make for complete the report. The conclusion explains about the problems occurs and
problem solving.
i
ABSTRAK
Setiap pelajar ijazah tahun 4 Universiti Teknikal Malaysia Melaka atau lebih di kenali
sebagai UTeM adalah wajib membuat Projek Sarjana Muda (PSM). Ini bertujuan untuk
meningkatkan lagi pengetahuan dan kemahiran dalam menyelesaikan masalah kajian
akedemik dengan kaedah saintifik, sistematik dan lahir sebagai seorang yang berdedikasi
dan persaingan yang profesional bagi megisi Hasil Program dan Program Objektif
Pembelajaran yang ditetapkan FKP. Tujuan utama projek ini adalah untuk menguji
kebersanan 3 jenis kepekatan cecair penyejuk dengan mengunakan mesin yang sesuai
iaitu Universal Cylindrical Grinder Model OD820S semasa mengkaji prestasi mesin
dalam kata erti lain factor kelurusan (straightness). Objektif projek ini pula adalah
mendedahkan pelajar tentang kepentingan kepekatan cecair penyejuk yang di gunakan
dalam proses pemesinan. Projek ini juga termasuk sesi latihan mengoperasikan mesin
demi memudahkan pelajar untuk memahami tentang prinsip mesin untuk menghasilkan
laporan penuh, persembahan projek dan laporan semasa projek ini. Kajian ini juga
mengambil kira tentang keupayaan melalui proses dan penjagaan. Semua data akan
dinilaikan daripada keputusan projek makmal. Sumbangan cecair penyejuk pula akan
dikaitkan dengan kelurusan dan di uji dengan mesin Mahr Formtester MMQ44, selepas
mendapat hasil ujian, penutup akan dibuat untuk melengkapkan laporan ini. Penutup
lapopran akan menceritakan tentang masalah yang terlibat dan penyelesaian masalah.
ii
DEDICATION
This work is dedicated to my parent, A Rahman Murad and Hamidah Harun.
Without whose caring support it would not have been possible, and to all my friends
and classmate for contributing to the success of my project and respect for
education.
iii
ACKNOWLEDGEMENT
In the name of Allah,The Most Gracious, Most Graceful.
Alhamdulillah, with full effort and patience in taking all challenges, Projek Sarjana
Muda (PSM) finally accomplished successfully.
A Special thanks to my supervisor, En. Mohd Amri Sulaiman for his very valuable
editorial advices, comments, guidance and support.
Besides, I would like to thank my beloved parents and family for giving endless
encouragement, motivation and support throughout my project. Last but not least, I
would like to thank my colleagues for their cooperation.
THANK YOU.
iv
TABLE OF CONTENT
ABSTRACT
i
ABSTRAK
ii
DEDICATION
iii
ACKNOWLEDGEMENT
iv
TABLE OF CONTENT
v
LIST OF TABLE
ix
LIST OF FIGURE
x
LIST ABBREVIATIONS
xii
1. INTRODUCTION
1
1.1
Background of Project
1
1.2
Problem Statement
2
1.3
Objectives
2
1.4
Scope Project
3
2. LITERATURE REVIEW
4
2.1
4
Introduction to Cylindrical Grinding Machines
2.1.1 Cylindrical grinding process characteristics
6
2.2
6
Universal Cylindrical Grinding Machine
2.2.1 Internal Grinding Machine
7
2.3
8
Grinding Wheel
2.3.1 Selecting the Grinding Wheel
9
2.4
Raw Material Selection
10
2.4.1 Stainless Steel SUS304
10
2.4.2 Composition
12
2.5
13
Straightness
2.5.1 Straightness Factor on Cylindrical Material
13
2.5.2 Cylindricality and Straightness of a Median Line
14
v
2.6
MarForm MMQ44 Formtester
15
2.7
Machines Description
16
2.8
Coolants
18
2.8.1 Cutting fluid
18
2.8.2 Liquids
18
2.8.3 Fluid Concentration
19
2.9
Refractometer
20
2.9.1 about the Brix Scale
20
2.9.2 Principles of Refractometers
21
2.9.3 Transparent Systems
21
2.9.4 Reflection Systems
22
3. METHODOLOGIES
23
3.1
23
Introduction
3.1.1 Summary flow chart of PSM
25
3.1.2 Diagram Flow Chart
26
3.2
Machining Introduction
27
3.3
Machining Parameters Setup
28
3.3.1 Parameter setting
28
3.3.2 Identification of the control factors and their level
28
3.3.3 Coolant Setup Parameters
28
3.3.4 Viscosity of Coolant Setup Procedure
30
3.4
32
Machining Samples
3.4.1 Machine Preparation before Machining Using
Cylindrical Grinding Machine
32
3.4.2 Machining Workpiece Using Cylindrical Grinding Machine
33
3.5
35
Measure and Analysis Data
3.5.1 Procedure to Operate
MarForm MMQ 44 Formtester Machine
vi
36
4. RESULTS AND ANALYSIS
39
4.1
Introduction
39
4.2
Result of Straightness
40
4.3
Analysis Graph for Result
41
4.3.1 Graph of 3 Brix Concentrations.
41
4.3.2 Graph of 6 Brix Concentrations.
42
4.3.3 Graph of 9 Brix Concentrations
43
4.4
Comparisons of Three Types Coolant Concentrations
43
4.5
Statistical/Hypothesis Test
45
4.5.1 Procedures in Hypothesis Testing
45
4.5.2 Hypothesis Test Procedure
46
4.5.2.1 Statistical Test Comparison between 3 Brix Concentrations
with 6 Brix Concentrations
46
4.5.2.2 Statistical Test Comparison between 3 Brix Concentrations
with 9 Brix Concentrations
48
4.5.2.3 Statistical Test Comparison between 6 Brix Concentrations
with 9 Brix Concentrations
50
4.5.3 Summary
52
5. DISCUSSION
53
5.1
Introduction
53
5.2
Influences in coolant concentrations
53
5.3
Influences in Grinding Operation
54
5.3.1 The Straightness Influence factor by Work Head speed
54
5.3.2 The Straightness Influence factor by Traverse Length
55
5.3.3 The Straightness Influence factor by Depth of cut (wheel infeed)
55
5.3.4 Dressing
55
5.3.5 Un-uniformity Dressing
56
5.3.6 Spark
56
5.4
Influence in Method of Measurement
57
5.5
Problems Encounter for the Study
57
vii
6. CONCLUSION
58
6.1
58
Conclusions
REFERENCE
60
APPENDIX A
APPENDIX B
APPENDIX C
APPENDIX D
APPENDIX E
APPENDIX F
APPENDIX G
APPENDIX H
viii
LIST OF TABLE
2.1
Composition Ranges for Grade Stainless Steel SUS304
11
3.1
The Level of Process Parameter for Cylindrical Grinding Machine
28
Table a: Gantt chart of Projek Sarjana Muda 1
24
Table b: Gantt chart of Projek Sarjana Muda 2
24
3.2
The data for experiment using Coolant A (3 brix concentration)
29
3.3
The data for experiment using Coolant B (6 brix concentration)
29
3.4
The data for experiment using Coolant C (9 brix concentration)
30
4.1
experimental Straightness result of coolant 3 brix for
40
stainless steel SUS304
4.2
experimental Straightness result of coolant 6 brix for
40
stainless steel SUS304
4.3
experimental Straightness result of coolant 9 brix for
41
stainless steel SUS304
4.4
Average value for each coolant type
43
4.5
Straightness Average for Coolant Type 3 Brix and Type 6 Brix
46
4.6
F-Test Two-Sample for Variances
46
4.7
T-Test: Two-Sample Assuming Unequal Variances
47
4.8
Straightness Average for Coolant Type 3 Brix and Type 9 Brix
48
4.9
F-Test Two-Sample for Variances
48
4.10
T-Test: Two-Sample Assuming Unequal Variances
49
4.11
Straightness Average for Coolant Type 6 Brix and Type 9 Brix
50
4.12
F-Test Two-Sample for Variances
50
4.13: T-Test: Two-Sample Assuming Unequal Variances
ix
51
LIST OF FIGURE
2.1
Universal Cylindrical Grinding Machine Model OD-820 H
6
2.2
Internal Grinding Machine
7
2.3
Stainless Steel SUS304 Raw Material
10
2.4
The Illustration of Straightness
13
2.5
Cylindricality Tolerance Specification
14
2.6:
Straightness of a Median Line Tolerance Specification
15
2.7
MarForm MMQ 44 Formtester to Measure Straightness
17
2.8
refractometer
20
2.9
transparent system
21
3.1
summary flow chart of PSM
25
3.2
Diagram Flow Chart
26
3.3
Flow chart of Machining Process Sequences
27
3.5
3 brix concentration of coolant (view through refractometer lens)
31
3.6
6 brix concentration of coolant (view through refractometer lens)
31
3.7
9 brix concentration of coolant (view through refractometer lens)
31
3.8
Workpiece Dimension
32
3.9
Band Saw Machine
32
3.10
Lathe Machine
33
3.11
Workpiece Dimension
33
3.12
Universal Cylindrical Grinding Machine model OD-820 H
35
3.13
MarForm MMQ 44 Formtester to Measure Straightness
36
3.14
Clean specimens sample
37
3.15
Setting the Centering and Tilting Parameters
37
3.16
Running the Centering and Tilting Operations
38
3.17
Graphical User Interface (GUI) of FORM PC software
38
x
4.1
graph plot for average straightness result of 3 brix concentration
41
4.2
graph plot for average straightness result of 6 brix concentration
42
4.3
graph plot for average straightness result of 9 brix concentration
43
4.4:
Graph of three type coolant concentration.
44
5.1:
Roughness of wheel effect by dressing lead (David J. Whitehouse).
56
xi
LIST OF ABBREVIATIONS
FKP
-
Fakulti Kejuruteraan Pembuatan
Mn
-
Manganese
Ni
-
Nickel
PSM
-
Projek Sarjana Muda
R
-
Radius
RPM
-
Revolution per Minute
S
-
Sulphur
Si
-
Silicon
Syn
-
Synthetic
UTeM
-
Universiti Teknikal Malaysia Melaka
In
-
Inch
In/min
-
Inch per Minute
Mm
-
Millimeter
µm
-
Micron Meter
µ
-
Micro
%
-
percent
xii
CHAPTER 1
INTRODUCTION
1.1
Background of Project
As one of the many tools available to manufacturing, grinding is a distinctive
technology that uses abrasives or synthetic minerals in loose or bonded form.
Grinding is one of most important technologies used by manufacturing today. Used
to machine and finishing the materials, grinding is in many cases the only method
available to engineers, particularly when ceramic or new composite materials are
involved. In other cases, grinding competes with other technologies and offers the
most economical way to produce precision component. As compared with other
machining processes, grinding is a costly operation that should be utilized under
optimal conditions.
Grinding is a finishing process used to improve surface finish, abrade hard materials,
and tighten the tolerance on flat and cylindrical surfaces by removing a small amount
of material. In grinding, an abrasive material rubs against the metal part and removes
tiny pieces of material. The abrasive material is typically on the surface of a wheel or
belt and abrades material in a way similar to sanding. On a microscopic scale, the
chip formation in grinding is the same as that found in other machining processes.
The abrasive action of grinding generates excessive heat so that flooding of the
cutting area with fluid is necessary. So, the coolant is one of the important things
during running the machine. In this case, the concentration of coolant use is 6 brix in
each machining. The performance of coolant is unknown. Both the viscosity of
coolant can give effect on to material and how many times the coolant can be use.
1
In Faculty of Manufacturing Laboratory in Universiti Teknikal Malaysia Melaka
there were new types of machine called Cylindrical grinding machine. Hence, this
report is mainly purpose to cover the study of performance coolant by using
cylindrical grinding. This study also to determine the machine capability in term of
producing high accuracy and precision, the highly product finishing that can
influence by straightness to the product.
1.2
Problem Statement
Coolant is an important factor during grinding surface process. However, the people
are not concern about the coolant condition during the process. But, the
concentration of coolant is the one of the factor gave effect on surface machining.
For this research, the contribution and effect will be test upon the material stainless
steel SUS304. This study will develop the appropriate parameter for cylindrical
grinding machining that can be used for practice and as a guide line for industry and
future research of student.
1.3
Objectives
(a) To study the contribution and effect of coolant to product surface while using
Cylindrical Grinding machine in FKP Laboratory
(b) To analyze the straightness factor of the finish stainless steel SUS304 product
using Mahr Formtester MMQ44 at the university Metrology Lab.
(c) To compare on straightness and quality on to three sets concentration of
coolant.(3,6,9 Brix)
2
1.4
Scope Project
The scope of this project is to test the effectiveness of three type
concentration of coolant with appropriate to the machining operation by using the
cylindrical grinding machine in order to study the machine performance in term of
straightness factor. The Universal Cylindrical Grinder Model OD820H will be used
in this study. The material used for machining is stainless steel SUS304. The
parameters that involve in this analysis are work head speed, depth of cut, and
traverse speed. Parameters such as coolant which is Pretech Cool Syn 3000 Green
with the 3 type brix of concentration and abrasive wheel speed are remains constant.
The straightness test for the specimen will be performed or conduct by using the
Mahr Formtester MMQ44 at the Metrology Lab and method applied is used to
determine the straightness.
3
CHAPTER 2
LITERATURE REVIEW
2.1
Introduction to Cylindrical Grinding Machines
A grinding machine is a machine tool used for producing very fine finishes or
making very light cuts, using an abrasive wheel as the cutting device. This wheel can
be made up of various sizes and types of stones, diamonds or of inorganic materials
(Anon. 2008, July 24). There are many types of grinding machine depend on the
surface of material that have to finishing. A machine grinding cylindrical surfaces is
called a cylindrical grinder. Machines designed for special functions, such as tool
grinding or cutting off, are designated according to their operation (Boothroyd, G.
and Knight, W. A. 2006).
Cylindrical grinding machines are used extensively in engineering workshops and
industries for finish pre-machined and heat-treated components. Grinders can rough
out and finish the work to fine tolerances. The smooth surface and great accuracy can
be obtained more economically on grinders than other machines.
In Manufacturing Laboratory, the machine that is use for this study is conventional
Universal Cylindrical Grinder Model OD 820H, with variable speed table and
manual wheel head in feed manufactured by SHARP Precision Machine Tools. The
machine has the capability to machine both of internal and external cylindrical
grinding.
In the cylindrical grinding machine, the work piece is supported and rotated between
centres. The head stock provides the low-speed rotational drive to the work piece and
is mounted, together with the tail stock on a work table that reciprocated horizontally
using the hydraulic drive. The grinding-wheel spindle is horizontal and parallel to the
4
axis of work piece rotation, and horizontal, hydraulic feed can be applied to the
wheel head in a direction normal to the axis of work piece rotation; this motion
known as in feed.
A cylindrical surface being generated using the traverse motion; an operation that
can be linked to cylindrical to cylindrical turning where the single point cutting tool
is replace by a grinding wheel. (Boothroyd, G. and Knight, W. A. 2006)
The cylindrical grinder traverses the work, to and fro, in repeated passes along the
length of the diameter, and the time to traverse is found using (Ostwarld, P.F. and
Munoz, J. 1997):
Time /pass =
Ls x Ts x D
(WP) 2fiπv
Where;
Ls
= Length of ground dimension on workpiece, in.
Ts
= Total rough or finish stock depth removed from diameter, in.
D
= Original workpiece diameter, in.
W
= Wheel width, in.
P
= Traverse for each work revolution in fraction of wheel width
fi
= Infeed of wheel per pass, in./pass
v
= Workpiece peripheral velocity, in. /min
5
2.1.1
Cylindrical grinding process characteristics
a) Produces straight, tapered, and formed cylindrical workpieces
b) Produces highly accurate surfaces and smooth finishes
c) Is primarily a final machining process
2.2
Universal Cylindrical Grinding Machine
The universal grinding machine is very similar in construction to a plain grinding
machine, except for the work head and the wheel head, both of which swivel. The
work head swivels on a graduated base to 10° either side of zero. The wheel head
platen not only swivels through 180° either side of zero, but is also mounted on a
slide that swivels independently through 80° to 90° either side of zero. Thus, the
slide can be set to the grinding angle required, and the platen swivelled through 90°
presenting the wheel/face parallel to the face to be ground. A semi-universal machine
in common use is very similar, except that the wheel platen and slide do not swivel
independently of each other.
Figure 2.1: Universal Cylindrical Grinding Machine Model OD 820H.
6
2.2.1 Internal Grinding Machine
(a) The essential elements of an internal grinding machine are:
i.
A work supporting chuck or faceplate.
ii.
A rotating grinding wheel.
From Figure 2.2 it shows that the grinding wheel is used to grind the internal surface
of a hole in a workpiece supported by the chuck or the face plate. The universal
grinder can be adapted for internal grinding by fitting an attachment. On modern
machines, this attachment is a standard fitting driven by its own motor and can be
quickly moved into position on the front of the wheelhead. Internal grinding is used
to grind cylindrical, tapered or formed holes in workpieces.
Figure 2.2: Internal Grinding Machine
7
ANALYSIS THE CONTRIBUTION AND EFFECT OF COOLANT
TO STRAIGHTNESS IN CYLINDRICAL GRINDING
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Process) with Honours.
by
HAIDZER ISA BIN A RAHMAN
FACULTY OF MANUFACTURING ENGINEERING
2009
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PSM
TAJUK:
“ ANALYSIS THE CONTRIBUTION AND EFFECT OF COOLANT TO STRAIGHTNESS IN
CYLINDRICAL GRINDING
”
SESI PENGAJIAN:
2 008/ 20 09 Semest er 2
Saya HAIDZER ISA BIN A RAHMAN
mengaku membenarkan laporan PSM ini disimpan di Perpust akaan Universit i Teknikal
Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :
1.
2.
3.
4.
Laporan PSM / t esis adalah hak milik Universit i Teknikal Malaysia Melaka dan
penulis.
Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan
unt uk t uj uan pengaj ian sahaj a dengan izin penulis.
Perpust akaan dibenarkan membuat salinan laporan PSM / t esis ini sebagai bahan
pert ukaran ant ara inst it usi pengaj ian t inggi.
*Sila t andakan ( √)
⁄
SULIT
(Mengandungi makl umat yang berdarj ah kesel amat an at au
kepent i ngan Mal aysia yang t er makt ub di dal am AKTA RAHSIA RASMI
1972)
TERHAD
(Mengandungi makl umat TERHAD yang t el ah dit ent ukan ol eh
organisasi / badan di mana penyel idikan dij al ankan)
TIDAK TERHAD
SU26 JALAN HJ HARON
BT 16 ½ KG SOLOK DUKU
78300 MASJID TANAH
MELAKA
Tarikh: _______________________
Cop Rasmi:
Tarikh: _______________________
* Jika laporan PSM i ni SULIT at au TERHAD, sila lampirkan surat daripada pihak organisasi berkenaan
dengan menyat akan sekali sebab dan t empoh t esi s ini perl u dikelaskan sebagai SULIT at au TERHAD.
DECLARATION
I hereby, declared this report entitled “Analysis The Contribution And Effect Of
Coolant To Surface Roughness In Cylindrical Grinding” is the result of my own
research except as cited in references.
Signature
:
………………………………………………..
Author’s Name
:
………………………………………………..
Date
:
……………..…………………………………
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a
partial fulfillment of the requirements for the degree of Bachelor of Manufacturing
Engineering (Manufacturing Process) with Honours. The member of the supervisory
committee is as follow:
(Signature of Supervisor)
………………………………………
(Official Stamp of Supervisor)
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a
partial fulfillment of the requirements for the degree of Bachelor of Manufacturing
Engineering (Manufacturing Process) with Honours. The members of the supervisory
committee are as follow:
(Signature of Principle Supervisor)
………………………………….
(Official Stamp of Principle Supervisor)
(Signature of Co-Supervisor)
………………………………
(Official Stamp of Co-Supervisor)
ABSTRACT
Every fourth year degree students of Universiti Teknikal Malaysia Melaka or known as
UTeM is compulsory to do Bachelor Degree Project (PSM). This is to improve
acknowledgments and skill in solve academic research problem with scientific,
systematic and born as a dedication and competence professional for full fill Program
Outcome (PO) and Program Educational Objective that fixed by FKP. The main point of
this project is to test the effectiveness of three type of coolant concentration with
appropriate to the machining operation by using Universal Cylindrical Grinder Model
OD820S in order to study the machine performance in term of straightness factor. The
objective of this project is to expose student to the important of coolant concentration use
in machining process. These projects are also including machine operating training
session in order to make student easily understand the machine principle to produce full
report writing, slide presentation and report during this project. The studies also concern
the student capability through process and maintenance. All data will be evaluated done
from the project lab result. The contribution of coolant will related to the straightness
and tested with Mahr Formtester MMQ44, after getting the result, conclusion will be able
to make for complete the report. The conclusion explains about the problems occurs and
problem solving.
i
ABSTRAK
Setiap pelajar ijazah tahun 4 Universiti Teknikal Malaysia Melaka atau lebih di kenali
sebagai UTeM adalah wajib membuat Projek Sarjana Muda (PSM). Ini bertujuan untuk
meningkatkan lagi pengetahuan dan kemahiran dalam menyelesaikan masalah kajian
akedemik dengan kaedah saintifik, sistematik dan lahir sebagai seorang yang berdedikasi
dan persaingan yang profesional bagi megisi Hasil Program dan Program Objektif
Pembelajaran yang ditetapkan FKP. Tujuan utama projek ini adalah untuk menguji
kebersanan 3 jenis kepekatan cecair penyejuk dengan mengunakan mesin yang sesuai
iaitu Universal Cylindrical Grinder Model OD820S semasa mengkaji prestasi mesin
dalam kata erti lain factor kelurusan (straightness). Objektif projek ini pula adalah
mendedahkan pelajar tentang kepentingan kepekatan cecair penyejuk yang di gunakan
dalam proses pemesinan. Projek ini juga termasuk sesi latihan mengoperasikan mesin
demi memudahkan pelajar untuk memahami tentang prinsip mesin untuk menghasilkan
laporan penuh, persembahan projek dan laporan semasa projek ini. Kajian ini juga
mengambil kira tentang keupayaan melalui proses dan penjagaan. Semua data akan
dinilaikan daripada keputusan projek makmal. Sumbangan cecair penyejuk pula akan
dikaitkan dengan kelurusan dan di uji dengan mesin Mahr Formtester MMQ44, selepas
mendapat hasil ujian, penutup akan dibuat untuk melengkapkan laporan ini. Penutup
lapopran akan menceritakan tentang masalah yang terlibat dan penyelesaian masalah.
ii
DEDICATION
This work is dedicated to my parent, A Rahman Murad and Hamidah Harun.
Without whose caring support it would not have been possible, and to all my friends
and classmate for contributing to the success of my project and respect for
education.
iii
ACKNOWLEDGEMENT
In the name of Allah,The Most Gracious, Most Graceful.
Alhamdulillah, with full effort and patience in taking all challenges, Projek Sarjana
Muda (PSM) finally accomplished successfully.
A Special thanks to my supervisor, En. Mohd Amri Sulaiman for his very valuable
editorial advices, comments, guidance and support.
Besides, I would like to thank my beloved parents and family for giving endless
encouragement, motivation and support throughout my project. Last but not least, I
would like to thank my colleagues for their cooperation.
THANK YOU.
iv
TABLE OF CONTENT
ABSTRACT
i
ABSTRAK
ii
DEDICATION
iii
ACKNOWLEDGEMENT
iv
TABLE OF CONTENT
v
LIST OF TABLE
ix
LIST OF FIGURE
x
LIST ABBREVIATIONS
xii
1. INTRODUCTION
1
1.1
Background of Project
1
1.2
Problem Statement
2
1.3
Objectives
2
1.4
Scope Project
3
2. LITERATURE REVIEW
4
2.1
4
Introduction to Cylindrical Grinding Machines
2.1.1 Cylindrical grinding process characteristics
6
2.2
6
Universal Cylindrical Grinding Machine
2.2.1 Internal Grinding Machine
7
2.3
8
Grinding Wheel
2.3.1 Selecting the Grinding Wheel
9
2.4
Raw Material Selection
10
2.4.1 Stainless Steel SUS304
10
2.4.2 Composition
12
2.5
13
Straightness
2.5.1 Straightness Factor on Cylindrical Material
13
2.5.2 Cylindricality and Straightness of a Median Line
14
v
2.6
MarForm MMQ44 Formtester
15
2.7
Machines Description
16
2.8
Coolants
18
2.8.1 Cutting fluid
18
2.8.2 Liquids
18
2.8.3 Fluid Concentration
19
2.9
Refractometer
20
2.9.1 about the Brix Scale
20
2.9.2 Principles of Refractometers
21
2.9.3 Transparent Systems
21
2.9.4 Reflection Systems
22
3. METHODOLOGIES
23
3.1
23
Introduction
3.1.1 Summary flow chart of PSM
25
3.1.2 Diagram Flow Chart
26
3.2
Machining Introduction
27
3.3
Machining Parameters Setup
28
3.3.1 Parameter setting
28
3.3.2 Identification of the control factors and their level
28
3.3.3 Coolant Setup Parameters
28
3.3.4 Viscosity of Coolant Setup Procedure
30
3.4
32
Machining Samples
3.4.1 Machine Preparation before Machining Using
Cylindrical Grinding Machine
32
3.4.2 Machining Workpiece Using Cylindrical Grinding Machine
33
3.5
35
Measure and Analysis Data
3.5.1 Procedure to Operate
MarForm MMQ 44 Formtester Machine
vi
36
4. RESULTS AND ANALYSIS
39
4.1
Introduction
39
4.2
Result of Straightness
40
4.3
Analysis Graph for Result
41
4.3.1 Graph of 3 Brix Concentrations.
41
4.3.2 Graph of 6 Brix Concentrations.
42
4.3.3 Graph of 9 Brix Concentrations
43
4.4
Comparisons of Three Types Coolant Concentrations
43
4.5
Statistical/Hypothesis Test
45
4.5.1 Procedures in Hypothesis Testing
45
4.5.2 Hypothesis Test Procedure
46
4.5.2.1 Statistical Test Comparison between 3 Brix Concentrations
with 6 Brix Concentrations
46
4.5.2.2 Statistical Test Comparison between 3 Brix Concentrations
with 9 Brix Concentrations
48
4.5.2.3 Statistical Test Comparison between 6 Brix Concentrations
with 9 Brix Concentrations
50
4.5.3 Summary
52
5. DISCUSSION
53
5.1
Introduction
53
5.2
Influences in coolant concentrations
53
5.3
Influences in Grinding Operation
54
5.3.1 The Straightness Influence factor by Work Head speed
54
5.3.2 The Straightness Influence factor by Traverse Length
55
5.3.3 The Straightness Influence factor by Depth of cut (wheel infeed)
55
5.3.4 Dressing
55
5.3.5 Un-uniformity Dressing
56
5.3.6 Spark
56
5.4
Influence in Method of Measurement
57
5.5
Problems Encounter for the Study
57
vii
6. CONCLUSION
58
6.1
58
Conclusions
REFERENCE
60
APPENDIX A
APPENDIX B
APPENDIX C
APPENDIX D
APPENDIX E
APPENDIX F
APPENDIX G
APPENDIX H
viii
LIST OF TABLE
2.1
Composition Ranges for Grade Stainless Steel SUS304
11
3.1
The Level of Process Parameter for Cylindrical Grinding Machine
28
Table a: Gantt chart of Projek Sarjana Muda 1
24
Table b: Gantt chart of Projek Sarjana Muda 2
24
3.2
The data for experiment using Coolant A (3 brix concentration)
29
3.3
The data for experiment using Coolant B (6 brix concentration)
29
3.4
The data for experiment using Coolant C (9 brix concentration)
30
4.1
experimental Straightness result of coolant 3 brix for
40
stainless steel SUS304
4.2
experimental Straightness result of coolant 6 brix for
40
stainless steel SUS304
4.3
experimental Straightness result of coolant 9 brix for
41
stainless steel SUS304
4.4
Average value for each coolant type
43
4.5
Straightness Average for Coolant Type 3 Brix and Type 6 Brix
46
4.6
F-Test Two-Sample for Variances
46
4.7
T-Test: Two-Sample Assuming Unequal Variances
47
4.8
Straightness Average for Coolant Type 3 Brix and Type 9 Brix
48
4.9
F-Test Two-Sample for Variances
48
4.10
T-Test: Two-Sample Assuming Unequal Variances
49
4.11
Straightness Average for Coolant Type 6 Brix and Type 9 Brix
50
4.12
F-Test Two-Sample for Variances
50
4.13: T-Test: Two-Sample Assuming Unequal Variances
ix
51
LIST OF FIGURE
2.1
Universal Cylindrical Grinding Machine Model OD-820 H
6
2.2
Internal Grinding Machine
7
2.3
Stainless Steel SUS304 Raw Material
10
2.4
The Illustration of Straightness
13
2.5
Cylindricality Tolerance Specification
14
2.6:
Straightness of a Median Line Tolerance Specification
15
2.7
MarForm MMQ 44 Formtester to Measure Straightness
17
2.8
refractometer
20
2.9
transparent system
21
3.1
summary flow chart of PSM
25
3.2
Diagram Flow Chart
26
3.3
Flow chart of Machining Process Sequences
27
3.5
3 brix concentration of coolant (view through refractometer lens)
31
3.6
6 brix concentration of coolant (view through refractometer lens)
31
3.7
9 brix concentration of coolant (view through refractometer lens)
31
3.8
Workpiece Dimension
32
3.9
Band Saw Machine
32
3.10
Lathe Machine
33
3.11
Workpiece Dimension
33
3.12
Universal Cylindrical Grinding Machine model OD-820 H
35
3.13
MarForm MMQ 44 Formtester to Measure Straightness
36
3.14
Clean specimens sample
37
3.15
Setting the Centering and Tilting Parameters
37
3.16
Running the Centering and Tilting Operations
38
3.17
Graphical User Interface (GUI) of FORM PC software
38
x
4.1
graph plot for average straightness result of 3 brix concentration
41
4.2
graph plot for average straightness result of 6 brix concentration
42
4.3
graph plot for average straightness result of 9 brix concentration
43
4.4:
Graph of three type coolant concentration.
44
5.1:
Roughness of wheel effect by dressing lead (David J. Whitehouse).
56
xi
LIST OF ABBREVIATIONS
FKP
-
Fakulti Kejuruteraan Pembuatan
Mn
-
Manganese
Ni
-
Nickel
PSM
-
Projek Sarjana Muda
R
-
Radius
RPM
-
Revolution per Minute
S
-
Sulphur
Si
-
Silicon
Syn
-
Synthetic
UTeM
-
Universiti Teknikal Malaysia Melaka
In
-
Inch
In/min
-
Inch per Minute
Mm
-
Millimeter
µm
-
Micron Meter
µ
-
Micro
%
-
percent
xii
CHAPTER 1
INTRODUCTION
1.1
Background of Project
As one of the many tools available to manufacturing, grinding is a distinctive
technology that uses abrasives or synthetic minerals in loose or bonded form.
Grinding is one of most important technologies used by manufacturing today. Used
to machine and finishing the materials, grinding is in many cases the only method
available to engineers, particularly when ceramic or new composite materials are
involved. In other cases, grinding competes with other technologies and offers the
most economical way to produce precision component. As compared with other
machining processes, grinding is a costly operation that should be utilized under
optimal conditions.
Grinding is a finishing process used to improve surface finish, abrade hard materials,
and tighten the tolerance on flat and cylindrical surfaces by removing a small amount
of material. In grinding, an abrasive material rubs against the metal part and removes
tiny pieces of material. The abrasive material is typically on the surface of a wheel or
belt and abrades material in a way similar to sanding. On a microscopic scale, the
chip formation in grinding is the same as that found in other machining processes.
The abrasive action of grinding generates excessive heat so that flooding of the
cutting area with fluid is necessary. So, the coolant is one of the important things
during running the machine. In this case, the concentration of coolant use is 6 brix in
each machining. The performance of coolant is unknown. Both the viscosity of
coolant can give effect on to material and how many times the coolant can be use.
1
In Faculty of Manufacturing Laboratory in Universiti Teknikal Malaysia Melaka
there were new types of machine called Cylindrical grinding machine. Hence, this
report is mainly purpose to cover the study of performance coolant by using
cylindrical grinding. This study also to determine the machine capability in term of
producing high accuracy and precision, the highly product finishing that can
influence by straightness to the product.
1.2
Problem Statement
Coolant is an important factor during grinding surface process. However, the people
are not concern about the coolant condition during the process. But, the
concentration of coolant is the one of the factor gave effect on surface machining.
For this research, the contribution and effect will be test upon the material stainless
steel SUS304. This study will develop the appropriate parameter for cylindrical
grinding machining that can be used for practice and as a guide line for industry and
future research of student.
1.3
Objectives
(a) To study the contribution and effect of coolant to product surface while using
Cylindrical Grinding machine in FKP Laboratory
(b) To analyze the straightness factor of the finish stainless steel SUS304 product
using Mahr Formtester MMQ44 at the university Metrology Lab.
(c) To compare on straightness and quality on to three sets concentration of
coolant.(3,6,9 Brix)
2
1.4
Scope Project
The scope of this project is to test the effectiveness of three type
concentration of coolant with appropriate to the machining operation by using the
cylindrical grinding machine in order to study the machine performance in term of
straightness factor. The Universal Cylindrical Grinder Model OD820H will be used
in this study. The material used for machining is stainless steel SUS304. The
parameters that involve in this analysis are work head speed, depth of cut, and
traverse speed. Parameters such as coolant which is Pretech Cool Syn 3000 Green
with the 3 type brix of concentration and abrasive wheel speed are remains constant.
The straightness test for the specimen will be performed or conduct by using the
Mahr Formtester MMQ44 at the Metrology Lab and method applied is used to
determine the straightness.
3
CHAPTER 2
LITERATURE REVIEW
2.1
Introduction to Cylindrical Grinding Machines
A grinding machine is a machine tool used for producing very fine finishes or
making very light cuts, using an abrasive wheel as the cutting device. This wheel can
be made up of various sizes and types of stones, diamonds or of inorganic materials
(Anon. 2008, July 24). There are many types of grinding machine depend on the
surface of material that have to finishing. A machine grinding cylindrical surfaces is
called a cylindrical grinder. Machines designed for special functions, such as tool
grinding or cutting off, are designated according to their operation (Boothroyd, G.
and Knight, W. A. 2006).
Cylindrical grinding machines are used extensively in engineering workshops and
industries for finish pre-machined and heat-treated components. Grinders can rough
out and finish the work to fine tolerances. The smooth surface and great accuracy can
be obtained more economically on grinders than other machines.
In Manufacturing Laboratory, the machine that is use for this study is conventional
Universal Cylindrical Grinder Model OD 820H, with variable speed table and
manual wheel head in feed manufactured by SHARP Precision Machine Tools. The
machine has the capability to machine both of internal and external cylindrical
grinding.
In the cylindrical grinding machine, the work piece is supported and rotated between
centres. The head stock provides the low-speed rotational drive to the work piece and
is mounted, together with the tail stock on a work table that reciprocated horizontally
using the hydraulic drive. The grinding-wheel spindle is horizontal and parallel to the
4
axis of work piece rotation, and horizontal, hydraulic feed can be applied to the
wheel head in a direction normal to the axis of work piece rotation; this motion
known as in feed.
A cylindrical surface being generated using the traverse motion; an operation that
can be linked to cylindrical to cylindrical turning where the single point cutting tool
is replace by a grinding wheel. (Boothroyd, G. and Knight, W. A. 2006)
The cylindrical grinder traverses the work, to and fro, in repeated passes along the
length of the diameter, and the time to traverse is found using (Ostwarld, P.F. and
Munoz, J. 1997):
Time /pass =
Ls x Ts x D
(WP) 2fiπv
Where;
Ls
= Length of ground dimension on workpiece, in.
Ts
= Total rough or finish stock depth removed from diameter, in.
D
= Original workpiece diameter, in.
W
= Wheel width, in.
P
= Traverse for each work revolution in fraction of wheel width
fi
= Infeed of wheel per pass, in./pass
v
= Workpiece peripheral velocity, in. /min
5
2.1.1
Cylindrical grinding process characteristics
a) Produces straight, tapered, and formed cylindrical workpieces
b) Produces highly accurate surfaces and smooth finishes
c) Is primarily a final machining process
2.2
Universal Cylindrical Grinding Machine
The universal grinding machine is very similar in construction to a plain grinding
machine, except for the work head and the wheel head, both of which swivel. The
work head swivels on a graduated base to 10° either side of zero. The wheel head
platen not only swivels through 180° either side of zero, but is also mounted on a
slide that swivels independently through 80° to 90° either side of zero. Thus, the
slide can be set to the grinding angle required, and the platen swivelled through 90°
presenting the wheel/face parallel to the face to be ground. A semi-universal machine
in common use is very similar, except that the wheel platen and slide do not swivel
independently of each other.
Figure 2.1: Universal Cylindrical Grinding Machine Model OD 820H.
6
2.2.1 Internal Grinding Machine
(a) The essential elements of an internal grinding machine are:
i.
A work supporting chuck or faceplate.
ii.
A rotating grinding wheel.
From Figure 2.2 it shows that the grinding wheel is used to grind the internal surface
of a hole in a workpiece supported by the chuck or the face plate. The universal
grinder can be adapted for internal grinding by fitting an attachment. On modern
machines, this attachment is a standard fitting driven by its own motor and can be
quickly moved into position on the front of the wheelhead. Internal grinding is used
to grind cylindrical, tapered or formed holes in workpieces.
Figure 2.2: Internal Grinding Machine
7