v
TABLE OF CONTENTS
Abstract i
Dedication iii
Acknowledgements iv
Table of Contents v
List of Figures ix
List of Tables xii
List of Abbreviations, Symbols, Specialized Nomenclature xiii
List of Appendices xiv
1. INTRODUCTION
1.1 Background of Project 1
1.2 Objective 2
1.3 Scope of Project 2
2. LITERATURE REVIEW
2.1 Introduction 4
2.2 Review: Grinding Due to Surface Finish 5
2.2.1 Reasons for Grinding 7
2.2.2 Machining removes excessive material 8
2.3 Review: Cylindrical Grinding 9
2.3.1 Introduction 9
2.3.2 Cylindrical Grinding Machine 9
2.3.3 Concept in Cylindrical Grinding 10
2.3.4 Method in Cylindrical Operation 14
2.3.5 Grinding Wheel 15
2.3.5.1 Wheel Properties 16
vi 2.3.5.2 Abrasive Grain Properties
17 2.3.5.3 Standard Marking System Chart
18 2.4 Parameter in Grinding
20 2.5 Review: Surface Integrity
21 2.5.1 Introduction
21 2.5.2 Review: Surface Roughness
22 2.5.2.1 Description of Surface Roughness
24 2.5.3 Surface Roughness Measurement
26 2.5.3.1 Direct Measurement Methods
27 2.5.3.2 Comparison Based Techniques
27 2.5.3.3 Non Contact Methods
27 2.5.3.4 On-process measurement
28 2.6 Review: Profilometer
29 2.6.1 Advantages of contact profilometers
30
3. METHODOLOGY
3.1 Studies of Cylindrical Grinding Operation and Process 32
3.1.1 Traverse Grinding Operations 34
3.1.2 Grinding Wheel Specification 34
3.1.3 Wheel Marking 35
3.2 Research of Parameter in Cylindrical Grinding Process 35
3.2.1 Wheel Speed 35
3.2.2 Traverse Speed 37
3.2.3 Depth of Cut 39
3.2.4 Parameter Selected for Further Studies 39
3.3 Training with Universal Cylindrical Grinder 41
3.4 Planning for Material Preparation 44
3.5 Perform Grinding Operation on Parameters Selected 45
3.5.1 Starting up Machine 46
3.5.2 Truing and Dressing a Grinding Wheel 48
vii 3.5.2.1 Truing
48 3.5.2.2 Dressing
49 3.5.2.3 Truing and Dressing a Grinding Wheel
49 3.5.3 Performing Grinding on the Workpiece
52 3.6 Study and Applying Measurement Method for Surface Roughness
59 3.7 Recording, Collecting and Analyzing Data Measurement and Data
of Surface Roughness 62
4. RESULT
4.1 Introduction 63
4.2 Area of Contact 63
4.3 Effect of Grinding Due To Surface Roughness 64
5. DISCUSSION
5.1 Introduction 71
5.2 Influences in Grinding Operation 71
5.3 Influences in Method of Measurements 72
5.4 The Surface Finish Factors by Spindle Speed 72
5.5 The Surface Roughness Factors by Traverse Speed 74
5.6 The Surface Roughness Factor by Grinding Wheel Infeed depth of cut 76 5.7 Factor of Traverse Length of Wheel to Sample
77 5.8 Relations between Parameters
79 5.9 Factor from Process in Grinding Operation
84 5.9.1 Un-uniformity Dressing
84 5.9.2 Spark
85 5.9.3 Grinding Fluid
86
6. CONCLUSION
