viii
TABLE OF CONTENTS
Declaration iii
Approval iv
Abstract v
Abstrak vi
Dedication vii
Acknowledgements viii
Table of Contents ix
List of Figures xiii
List of Tables xv
List of Abbreviations, Symbols, Specialized Nomenclature xvi
List of Appendices xvii
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 Introduction
to Cylindrical
Grinding Machines
4 2.2
Types of
Machine 5
2.2.1 Plain
cylindrical grinding
machine 6
2.2.2 Universal
cylindrical grinding
machine 7
2.2.3 Internal
Grinding Machine
8 2.3
Machine Specification 9
2.4 Cylindrical Grinding Machine Part 11
2.4.1 Tailstock 11
2.4.2 Headstock 12
ix
2.4.3
Wheel head 13
2.4.4
Grinding Wheel 14
2.4.5
Grinding Wheel Specification 16
2.4.5.1
Abrasives 16
2.4.5.2
Wheel Markings 17
2.4.5.3
Wheel Shapes and Sizes 19
2.4.5.4
Selecting the Grinding Wheel 20
2.5
Cylindrical Grinding Cycles 21
2.6
Cylindrical Grinding Operations 21
2.7
Cylindrical Grinding Work Speed 22
2.7.1 Correct Work Speed 22
2.7.2 Rules for Work Speed 23
2.8 Cylindrical Grinding Traverse Speed 23
2.9 Raw Material Selection 25
2.9.1 Mild Steel SS400 25
2.9.2 Stainless Steel SUS 304 27
2.9.2.1 Composition 29
2.9.2.2 Mechanical Properties 30
2.10 Straightness 30
2.10.1 Straightness Factor on Cylindrical Material 31
2.10.2 Cylindricity and Straightness of a Median Line 31
2.10.3 MarForm MMQ44 Formtester 33
2.10.3.1Machines Description 34
2.11 Introduction to Design Of Experiments DOE 36
2.11.1 Classical and Taguchi Experiments 36
2.11.2 Choice of Optimum Results 38
3. METHODOLOGY 39
3.1 Introduction 39
3.2 Project Process Planning 40
3.2.1 Machining Introduction 43
x 3.3 Machining Parameters Setup
44 3.3.1 Parameter setting
44 3.3.2 Identification of the control factors and their level
44 3.4 Machining Samples
48 3.4.1 Machine Preparation before Machining Using Cylindrical Grinding 48
Machine 3.4.2 Machining Workpiece Using Cylindrical Grinding Machine
50 3.5 Measure and Analysis Data
51 3.5.1 Procedure to Operate MarForm MMQ 44 Formtester Machine
52 3.6 Result Analysis
56 3.7 Discussion
56 3.7 Conclusion
56
4. RESULTS ANALYSIS 50
4.1 Introduction 57
4.2 Findings and Result of Straightness 58
4.3 Analysis for Factorial Design Experiment for Mild Steel SS400 59
4.3.1 Significant Parameter of Straightness for Mild Steel SS400 59
4.3.2 Normal Probability Plot of Effects on Straightness for Mild Steel SS400 60 4.3.3 Pareto Chart of the Effects on Straightness for Mild Steel SS400 61
4.3.4 Main Effects Plot on Straightness for Mild Steel SS400 62
4.3.5 Interaction between Parameters on Straightness for Mild Steel SS400 63 4.3.6 Mathematical Model Development on Straightness for Mild Steel SS400 65
4.4 Analysis for Factorial Design Experiment for Stainless Steel SUS304 67
4.4.1 Significant Parameter of Straightness for Stainless Steel SUS304 67 4.4.2 Normal Probability Plot of Effects on Straightness for Stainless
68 Steel SUS304
4.4.3 Pareto Chart of the Effects on Straightness for Stainless Steel SUS304 69 4.4.4 Main Effects Plot on Straightness for Stainless Steel SUS304
70 4.4.5 Interaction Plot Data Means on Straightness for Stainless
71
xi Steel SUS304
4.4.6 Mathematical Model Development on Straightness for Stainless 73
Steel SUS304
5. DISCUSSION 74
