scholarly journals Optimization of Grinding Parameters for the Workpiece Surface and Material Removal Rate in the Belt Grinding Process for Polishing and Deburring of 45 Steel

2020 ◽  
Vol 10 (18) ◽  
pp. 6314
Author(s):  
Fengping Li ◽  
Yao Xue ◽  
Zhengya Zhang ◽  
Wenlei Song ◽  
Jiawei Xiang
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Weighting Coefficient ◽  
Grinding Process ◽  
Feed Speed ◽  
Belt Grinding ◽  
Optimal Value ◽  
Grinding Efficiency

Surface roughness and the material removal rate (MRR) are two important indicators during the grinding process. The former determines the surface quality while the latter reflects the grinding efficiency directly. In this paper, the two indicators are taken into consideration simultaneously and differently by converting them into a comprehensive goal with using weighting objective method. A prediction model was established for each comprehensive goal with each different combination of surface roughness and MRR weighting coefficient. The optimal value of abrasive size, contact force, belt linear speed, and feed speed were obtained under different grinding situations by using a central composite design (CCD) combined with response surface analysis. The experimental results showed that the comprehensive goal can be used effectively as an indicator to control the grinding performance and improve the optimization process.

scholarly journals Relationship between Pressure and Output Parameters in Belt Grinding of Steels and Nickel Alloy

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4704
Author(s):  
Nelli Vladimirovna Syreyshchikova ◽  
Danil Yurievich Pimenov ◽  
Munish Kumar Gupta ◽  
Krzysztof Nadolny ◽  
Khaled Giasin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Process ◽  
Belt Grinding ◽  
Flat Surfaces ◽  
Heat Resistant ◽  
Steel Aisi

Belt grinding of flat surfaces of typical parts made of steel and alloys, such as grooves, shoulders, ends, and long workpieces, is a good alternative to milling. Several factors can influence the belt grinding process of flat surfaces of metals, such as cutting speed and pressure. In this work, the importance of pressure in the belt grinding was investigated in terms of technological and experimental aspects. The grinding experiments were performed on structural alloy steel 30KhGSN2/30KhGSNA, structural carbon steel AISI 1045, corrosion-resistant and heat-resistant stainless steel AISI 321, and heat-resistant nickel alloy KHN77TYuR. The performance of the grinding belt was investigated in terms of surface roughness, material removal rate (MRR), grinding belt wear, performance index. Estimated indicators of the belt grinding process were developed: cutting ability; reduced cutting ability for belt grinding of steels and heat-resistant alloy. It was found that with an increase in pressure p, the surface roughness of the processed surface Ra decreased while the tool wear VB and MRR increased. With a decrease in plasticity and difficulty of machinability, the roughness, material removal rate, reduced cutting capacity (Performance index) qper, material removal Q decreased, and the tool wear VB increased. The obtained research results can be used by technologists when creating belt grinding operations for steels and alloys to ensure the required performance is met.

scholarly journals Study on the Effect of Grinding Pressure on Material Removal Behavior Performed on a Self-Designed Passive Grinding Simulator

2021 ◽  
Vol 11 (9) ◽  
pp. 4128
Author(s):  
Peng-Zhan Liu ◽  
Wen-Jun Zou ◽  
Jin Peng ◽  
Xu-Dong Song ◽  
Fu-Ren Xiao
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Service Life ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Temperature ◽  
Grinding Efficiency

Passive grinding is a new rail grinding strategy. In this work, the influence of grinding pressure on the removal behaviors of rail material in passive grinding was investigated by using a self-designed passive grinding simulator. Meanwhile, the surface morphology of the rail and grinding wheel were observed, and the grinding force and temperature were measured during the experiment. Results show that the increase of grinding pressure leads to the rise of rail removal rate, i.e., grinding efficiency, surface roughness, residual stress, grinding force and grinding temperature. Inversely, the enhancement of grinding pressure and grinding force will reduce the grinding ratio, which indicates that service life of grinding wheel decreases. The debris presents dissimilar morphology under different grinding pressure, which reflects the distinction in grinding process. Therefore, for rail passive grinding, the appropriate grinding pressure should be selected to balance the grinding quality and the use of grinding wheel.

Genetic Programming for Grinding Surface Roughness Modelling

2012 ◽  
Vol 565 ◽  
pp. 183-189
Author(s):  
Xun Chen ◽  
Asma Alabed
Keyword(s):  
Surface Roughness ◽  
Genetic Programming ◽  
Material Removal Rate ◽  
Surface Finish ◽  
Material Removal ◽  
Removal Rate ◽  
High Accuracy ◽  
Grinding Process ◽  
Reliable Prediction ◽  
Modelling Process

Grinding process is commonly selected for finishing operation because grinding has high accuracy and surface finish with a relatively high material removal rate. One of the most common issues in grinding process planning is to determine grinding condition for required surface roughness. This paper presents a feasibility study on grinding surface roughness modelling using genetic programming (GP) method. It has successfully demonstrated that GP could provide reliable prediction and has advantages over other established methods in terms of dealing with missing data during modelling process.

Study of the Cutting Parameters on Surface Roughness and Material Removal Rate in Hard Turning of UHMWPE

2020 ◽  
Author(s):  
César Oswaldo Aguilera-Ojeda ◽  
Alberto Saldaña-Robles ◽  
Agustín Vidal-Lesso ◽  
Israel Martínez-Ramírez ◽  
Eduardo Aguilera-Gómez
Keyword(s):  
Surface Roughness ◽  
Predictive Model ◽  
Material Removal Rate ◽  
Surface Finish ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Turning Process

Abstract The surface finish of industrial components has an important role in their performance and lifetime. Therefore, it is crucial to find the cutting parameters that provide the best surface finish. In this work, an experimental study of the effect of cutting parameters on ultra-high molecular weight polyethylene (UHMWPE) by a turning process was carried out. Today, the UHMWPE polymer continues to find applications mainly in the automotive industry and biomechanics because it is resistant to impact and corrosive materials to use. A face-centered Central Composite Design (CCD) and Response Surface Methodology (RSM) were applied to evaluate the influence of the cutting speed (Vc), feed rate (f) and depth of cut (ap) of the turning operation on the Average Surface Roughness (Ra) and Material Removal Rate (MRR). Results allowed obtaining an adjusted multivariable regression model that describes the behavior of the Ra that depends on the cutting parameters in the turning process. The predictive model of Ra showed that it fits well with a correlation coefficient (R2) around 0.9683 to the experimental data for Ra. The ANOVA results for Ra showed that the feed is the most significant factor with a contribution of 42.3 % for the term f 2, while the speed and depth of cut do not affect Ra with contributions of 0.19% and 0.18%, respectively. A reduction of feed from 0.30 to 0.18 mm·rev−1 produces a decrease in surface roughness from 6.68 to 3.81 μm. However, if the feed continued to reduce an increase in surface roughness, a feed of 0.05 mm·rev−1 induces a surface roughness of 14.93 μm. Feeds less than 0.18 mm·rev−1 cause a heat generation during turning that increases the temperature in the process zone, producing surface roughness damage of the UHMWPE polymer. Also, the results for MRR demonstrated that all of the cutting parameters are significant with contributions of 31.4%, 27.4% and 15.4% to feed, speed, and depth of cut, respectively. The desirability function allowed optimizing the cutting parameters (Vc = 250 m·min−1, ap = 1.5 mm y f = 0.27 mm·rev−1) to obtain a minimum surface roughness (Ra = 4.3 μm) with a maximum material removal rate (MMR = 97.1 cm3·min−1). Finally, the predictive model of Ra can be used in the industry to obtain predictions on the experimental range analyzed, reducing the surface roughness and the manufacturing time of UHMWPE cylindrical components.

Experimental Research on Ultrasonic Lapping Al2O3 Engineering Ceramics Using Fixed Oilstones

2006 ◽  
Vol 304-305 ◽  
pp. 340-344 ◽  
Author(s):  
G.F. Gao ◽  
Bo Zhao ◽  
C.S. Liu ◽  
Qing Hua Kong
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Ground Surface ◽  
Average Diameter ◽  
Engineering Ceramic ◽  
Optimal Value ◽  
Ground Surface Roughness ◽  
Experimental Researches

Experimental researches on material removal rate and surface roughness of Al2O3 engineering ceramic guide-pulley lapping were carried out using W20 and W5 fixed oilstones by self-developed ultrasonic lapping tool both with and without ultrasonic assistance. Experimental results show that lapping speed, lapping pressure and grain size produce different effects on the lapped surface roughness and material removal rate. The material removal rate in ultrasonic lapping process is two times as large as that in traditional lapping, and the ground surface roughness is superior to that in common machining method. The material removal rate increases along with the average diameter of grains and the lapping speed both in ultrasonic lapping and traditional lapping. In traditional lapping process the material removal rate becomes bigger along with the lapping force, while in ultrasonic lapping it gets the optimal value with the lapping force 450N. The value of lapped surface roughness increases along with the lapping speed in traditional lapping, on the contrary it decreases contrast to the lapping speed until 250rpm in the ultrasonic lapping. The value of traditionally lapped surface roughness decreases contrast to the lapping force, whereas it achieves the minimum with the lapping force 450N with ultrasonic assistance.

Investigation of Surface Roughness and Material Removal Rate on Machining of TIB2 Reinforced Aluminum 6063 Composites: A Taguchi’s Approach

2020 ◽  
Vol 22 (4) ◽  
pp. 1319-1328
Author(s):  
L. Emmanual ◽  
T. Karthikeyan
Keyword(s):  
Surface Roughness ◽  
Analysis Of Variance ◽  
Material Removal Rate ◽  
Orthogonal Array ◽  
Metal Matrix ◽  
Material Removal ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Tib2 Particles

AbstractThe utilization of TiB2 particles reinforced aluminum (Al6063) metal matrix composite materials in many different engineering fields has undergone a tremendous increase. Accordingly, the need of accurate machining of composites has increased enormously; an attempt has been made to assess the factors influencing surface roughness and material removal rate on machining the composite. The orthogonal array, the signal-to-noise ratio, and analysis of variance were employed to study the performance characteristics in turning operations of 5 and 10 wt. % TiB2 particles reinforced aluminum (Al6063) metal matrix composites. Taguchi method was used to find the optimal cutting factors for surface roughness (Ra) and material removal rate (MRR). Three cutting factors namely speed; feed and depth of cut were optimized with considerations of Ra and MRR. The experimental plan and analysis was based on the Taguchi L27 orthogonal array with three cutting factors using carbide tool (K20). The optimal parametric combination for K20 carbide insert was found to be feed, speed and depth of cut. The analysis of variance (ANOVA) result shows that feed the most significant process parameter on surface roughness followed by speed. For MRR result show that the speed and the feed are the significant parameters followed by the composition of composite material.

scholarly journals Application of Taguchi and RSM Parameters on Surface Roughness and Material Removal Rate of AA6082T6

2021 ◽  
Vol 2070 (1) ◽  
pp. 012211
Author(s):  
Harish Mugutkar ◽  
N. Tamiloli
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Feed Speed ◽  
Expulsion Rate ◽  
The Impact ◽  
Test Outcomes ◽  
Carbide Insert ◽  
The Ideal

Abstract Taguchi and Response Surface Methodologies (RSM) for Surface Roughness (SR), and Material Removal Rate (MRR) in end processing of AA6082T6 with tungsten carbide Insert. The Experiments have been driven using the Taguchi plan. The cutting boundaries are feed, speed, and profundity of cut. The impact of machining boundaries and to assessed the ideal cuttings condition to surface unpleasantness and material expulsion rate. A second-request model has been work between the cutting limits and the machining limits to recognize out the SR and MRR by using reaction surface strategy. The test outcomes have shown the most basic factor in the surface unpleasantness is speed (31.068%) and in the material evacuation rate is profundity of cut (51.9404%). The anticipated qualities are affirmed by utilizing affirmation tests.

scholarly journals COMBINATION OF TAGUCHI METHOD, MOORA AND COPRAS TECHNIQUES IN MULTI-OBJECTIVE OPTIMIZATION OF SURFACE GRINDING PROCESS

2020 ◽  
pp. 1-9
Author(s):  
Do Duc Trung
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Optimization Problem ◽  
Removal Rate ◽  
Optimization Techniques ◽  
Surface Grinding ◽  
Grinding Process ◽  
Multi Objective Optimization ◽  
Multi Objective

This study presentes a combination method of several optimization techniques and Taguchi method to solve the multi-objective optimization problem for surface grinding process of SKD11 steel. The optimization techniques that were used in this study were Multi-Objective Optimization on basis of Ratio Analysis (MOORA) and Complex Proportional Assessment (COPRAS). In surface grinding process, two parameters that were chosen as the evaluation creterias were surface roughness (Ra) and material removal rate (MRR). The orthogonal Taguchi L16 matrix was chosen to design the experimental matrix with two input parameters namely workpiece velocity and depth of cut.  The two optimization techniques that mentioned above were applied to solve the multi-objective optimization problem in the grinding process. Using two above techniques, the optimized results of the cutting parameters were the same. The optimal workpiece velocity and cutting depth were 20 m/min and 0.02 mm. Corresponding to these optimal values of the workpiece velocity and cutting depth, the surface roughness and material removal rate were 1.16 µm and 86.67 mm3/s. These proposed techniques and method can be used to improve the quality and effectiveness of grinding processes by reducing the surface roughness and increasing the material removal rate.

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