International Journal of Basic and Applied Science Research (IJBASR)

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The Influence of Cutting Parameter of Surface

Grinder on the Surface Finishing and Surface
Hardness of Structural Steel
Mr. Kamlesh Pal1 and Vaibhav Shivhare2
1,2
MITS College Mechanical Engineering Department Gwalior
E-mail: [email protected], [email protected]

Abstract: The grinding and finishing processes are used for final work p iece or the work piece can be moved whilst the grind
finish and super finish. Out of various types of grinding, the most head stay in fixed position. Grinding, as a complex machin ing
common one is surface grinding. This process is accompanied by process with large numbers of parameters influencing each
certain amount of metal removal. This process can give a surface
other, can be considered as a process where the grinding wheel
finish in a range of 1.25µm to 0.25µ. Grinding is a metal cutting
operation performed by means of a rotating abrasive tool Called engage with the workpiece at a high speed. To achieve better
grinding. Surface grinding is the method of grinding designed to process control a model is required to pred ict and demonstrate
carry out the removal of metal from a part or parts less expensively the whole life cycle performance in relation to the process
and with greater precision than could be achieved by machining input parameters. Grinding machine remove material fro m the
processes with cutting tools of steel, or by hand or machine filing. work p iece by abrasion. Which can generate substantial
Surface grinding is particularly effective for parts having hard spots amount of heat. They therefore incorporate a coolant to cool
that would seriously blunt or impede a cutting tool, or where a hard the work piece so that it does not over heat and go outside it
superficial scale causes similar trouble in machining proper. The tolerance. In spite of that, a question related to the optimu m
type of grinding finish resulting is often so good that a later polishing
grinding cutting parameters wh ich can induced superficial
operation can be dispensed with, but for this to be so well designed
machine is essential. This paper show the effect of cutting parameters hardening together with great surface roughness were never
of grinding process on the surface finishing and hardness of being answered. [3}
structural steel. The cutting parameter includes such as work speed,
feed, depth of cut and coo lant flow etc. The influence of the cutting Therefore, this study work have been propose in order to
parameter toward surface roughness and surface hardness had been determine the optimu m parameter and co relation between
determined. Therefore, good surface roughness and the superficial hardness of the
this study work has been propose in order to determine the optimum work piece.
parameter and correlation between good surface roughness and the
surface hardness of the work piece. [2]
2. LITREATURE REVIEW
Keywords: Speed, Infeed, Cross feed, Depth of cut.
In the past few decades, there has been an increase in research
1. INTRODUCTION on grinding due to it ever increasing application in
manufacturing industry. Also the complexity o f the grinding
Grinding is a co mplex metal cutting process, which for many process demands more and more attention to understand the
centuries has been perfected via study and complex analytical grinding process better. In this section relevant research work
approach. It is well known that this machining process on grinding is rev iewed. Grinding is a material-removal
consume mo re energies co mpare to another machin ing process in which abrasive part icles are contained in a bonded
methods. Grinding is traditionally a finishing process grinding wheel that operates at very high surface speeds.[7].
emp loyed to apply high quality surfaces to a work piece. This The grinding wheel is usually disk-shaped, and is precisely
was possible due to the increased number of cutting edges balanced for high rotational speeds. Surface grinding involves
present on a grinding wheel over that of conventional single grinding flat surfaces and is one of the most co mmon grinding
point cutting tools. The relationship between cutting condition operations (Fig. 1.1). Typically, the work p iece is secured on a
and the surface finish of the work piece has been establish and magnetic chuck attached to the work table of the grinder (Fig.
verified through series of studies. Grinding wheel consist of 1.2). Non magnetic materials generally are held by v ises,
power driven grinding wheel driven at the required speed and special fixtures, vacuu m chucks, or double-sided adhesive
a bed with a fixture to guide and hold the work piece. The tapes. The rotating grinding wheel consists of many cutting
grinding head can be controlled to travelled across the fixed teeth (the abrasive particles), and the work is fed relative to
12 Mr. Kamlesh Pal and Vaibhav Shivhare

the wheel to accomplish material removal. A straight wheel is analysis of the grinding process. J.Kopac and P.Krajnik[1]
mounted on the horizontal spindle of the grinder. Traverse (2006) proposed the high performance that grinding is
grinding occurs as the table reciprocates longitudinally and essential to achieve high dimensional accuracy and surface
feeds laterally after each stroke. In plunge grinding, the wheel integrity of ground component at optimu m cost efficiency at
is moved radially into the work piece, as it is when grinding a increased grinding cutting speed is the most important factor
groove (Fig. 1.1 & 1.2). (S. Malkin, 1984) in achieving imp roved quality tool life and productivity. In
this way the advantages of HSG (high speed grinding ) refer to
a reduction in the grinding forces, the grinding wheel wear and
work piece surface roughness. An increase in temperature in
the grinding zone that in turn can cause thermal subsurface
damage.[6]

3. PROB LEM DEFINATION

Although the grinding process has been a topic of extensive
research for the last 20 year, a co mplete understanding of the
Fig. 1.1 process has yet to be achieved. As we all known, grinding is
complex cutting process with large nu mber of interacting
parameters. the concern parameters in this study include wheel
speed, feed and depth of cut .Several informat ion has been
extracted fro m prev ious study. a carbon content is crucial to
induce the superficial hardening process to take place in
grinding. It is also suggested that the severe cutting condition
will assist in martensite formation in microstructure level of
work piece. In addition, a good surface fin ish is also a
response to the experiment done. How the cutting parameters
influence the value of the surface roughness and the surface
Fig. 1.2 hardness will be determine through the study work.[5]
1 Schemat ic illustration of various surface grinding operation 4. MET HODOLOGY
(a) Horizontal- spindle surface grinder: t raverse grinding (b)
Horizontal-spindle surface grinder: plunge grinding (S. It is an extremely versatile mach ine used to perform a variety
Malkin, 1984) (S. Malkin, 1984) of grinding operation, surface ,cylindrical or co mplex shapes
The image shows a manually operated setup. However highly
automated computer numerical control machine are becoming
increasingly co mmon due to the co mplexit ies involved in the
process. The operation of the machine required high level of
skill. The two main skills needed understand of the
relationship between the grinding wheel and the metal being
cut and knowledge of tool geometry. All experiments were
conducted with the surface grinder and the specified grinding
wheel and the dimension given. It is to guarantee that work
piece was in the best condition (i.e. with a very sharp plane
Fig. 1.3: S chematic illustration of a horizontal spindle surface cutting surfaces to guarantee equal conditions for all the
grinder experiments). The grinding will be done in 1cm depth of the
work piece.
Grinding has been with us fro m. earliest times when it was
used to grind stones to the required shape for cooking and 5. WORKPIECE SPECIFICATION
eating utensils (Malkin, 1989). It can be described as a
Machining process that utilizes hard abrasive particles as the The components material is a mediu m carbon steel EN-18. It
cutting mediu m, Whitehouse (1994) categorizes his into three is a relatively h igh machinable carbon steel with good
main types of processes namely: mechanical strength. For chemical properties; it is contain C
(0.35%-0.45%), Si(0.10%-0.35%), Mn(0.60%-0.95%), Cr
Grinding: Fixed grain, h igh speed. The review cover three area (0.85%-1.15%) S(0.050%) and P(0.050%). The normal usage
in grinding process namely ,ground surface topography of the material are connecting rod, die forging, guide plates,
generation, modeling of the grinding system and dynamic jigs, fixtu res ,die block ,axles ,gears and simples structural

International Journal of Basic and Applied Science Research (IJBASR)

Print ISSN: , Online ISSN: , Vo lu me 1, Nu mber 1, December, 2014
The Influence of Cutting Parameter of Surface Grinder on the Surface Finishing and Surface Hardness of Structural Steel 13

components. The dimension of the work piece is 6cm X 4cm

X 3cm. It is important to conduct the experiment under chatter free
condition, same dressing condition (cross feed rate 0.1
SURFACE GRINDER SPECIFICATION mm/ rev) and the use of single point diamond. The coolant
flow will be ensuring constant throughout the cutting process.
M ax. Table grinding W XL 200 x 450 mm
The spark out time will be 0.1 s. the depth of dressing will be
M ax. Travel 250 x 500 mm
0.02mm. The experiment run and the measurement process
M ax. Grinding Hight under Wheel 225 mm
will be managed in same day
Grinding Wheel Size 180x 13x31.75mm
Power of Spindle M otor 1 HP
R.P.M . 2800 RPM 7. RES ULT AND CONCLUS ION
Hydraulic Pressure 12 kg/cm2
Hydraulic P ump M otor 1 HP The grinding operation parameters and the value of surface
Tank Capacity 35 Ltrs. roughness and surface hardness obtain
Longitudinal Table Speed M ax. 15 m/min.
Power Cross Feed 2000 mm/min RUN v f d t µm HB
Least Count of M icro feed .002 Roughne Hardne
Net Weight (Approx.) 1100 kg ss ss
Wooden Case Dimension (Approx.) 1050 x 1500 x 1 700 1 12.8 7.5 12.5 0.03 0.51 252
2 25 12 5 0.03 2.04 260
EXPERIMENTAL DES IGN TAB LE 3 12.8 7.5 12.5 0.03 0.28 258
4 25 3 20 0.06 1.34 271
GRINDING FACTORS S YMBOLS UNIT 5 25 3 20 0.06 0.8 263
SPEED v m/min 6 0.6 3 5 0.06 0.21 232
INFEED d µm 7 0.6 3 20 0.09 0.64 258
CROSS FEED f mm/pass 8 0.6 12 5 0.06 0.68 251
DEPTH OF CUT t mm 9 0.6 12 20 0.09 1.23 260
10 25 3 20 0.09 0.41 252
6. EXPERIMENTAL PROCEDUR E 11 25 12 20 0.09 2.46 271
12 25 3 5 0.06 0.68 265
Design of experiment is required if we wish to ext ract
mean ingful conclusions from the measured responses. On the basis of present study following conclusion can be
Adequate experimental design requires competent process drawn
knowledge fo r selection of their factors and their levels had 1. When the infeed, cross feed and speed increase, the
could possibly significantly influence the response. Therefore, superficial hardness of the grounded EN-18 mediu m
the experimental design appointment has been performed with carbon steel also increase.
the reference to prev ious experiment by O. Zu rita et. al. 2. There were interaction between cross feed and speed &
(2002). 68 infeed and speed; however, generally, in the interaction,
the surface hardness increased as the both parameters
Measuring equipment used in this experiment are given belo w increased.
1. Surface Roughness Measurement 3. When comparing the grinding parameters, the speed and
2. Superficial Hardness measurement the infeed has the most effect onto the surface hardness of
3. Dial guage EN-18 med iu m carbon steel.
4. Speed and Cross feed were the most significant grinding
EXPERIMENTAL DES IGN MATRIX parameters toward the surface roughness of grounded EN-
18 mediu m carbon steel.
RUN v f d t
5. Generally, the surface roughness was increase as the value
1 12.8 7.5 12.5 0.03
2 25 12 5 0.03 of the speed and cross feed increase.
3 12.8 7.5 12.5 0.03 8. ACKNOWLEDGMENT
4 25 3 20 0.06
5 25 3 20 0.06 I kamlesh pal wish to acknowledge Prof.Vaibhav shivhare and
6 0.6 3 5 0.06
Madhav Institute Technology & science of Gwalior for their
7 0.6 3 20 0.09
continuing support in this research project
8 0.6 12 5 0.06
9 0.6 12 20 0.09
10 25 3 20 0.09
11 25 12 20 0.09
12 25 3 5 0.06

International Journal of Basic and Applied Science Research (IJBASR)

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14 Mr. Kamlesh Pal and Vaibhav Shivhare

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Annals of the CIRP, pp. 1-18.
[1] J Kopac and P. Krajnik. High performance grinding facult of [5] A survey of recent grinding wheel topography models. Doman,
M echanical Engg. Journal of material processing technology.Vol D.A., Warkentin, A. and Bauer, R. 2006, International Journal
125. 2006, pp. 278-284 of M achine Tools & M anufacture, Vol. 46, pp. 343-352.
[2] Brinksmeler, E. and Brockhoff, T. (1996). Utilization of [6] The use of the size effect in grinding for work-hardening.
Grinding Heat as a New Heat Treatment Process. CIRP Vol. 45. Heinzel, C. and Bleil, N. 1, 2007, Annals of the CIRP, Vol. 56,
[3] M alkin,.S. (1984) Grinding of metal: Theory and Application, pp. 327-330.
Applied Metalworking. American Society for M etals, vol. 3, No. [7] A comparison of topographic characterization parameters in
2 grinding. Terry, Andrew J. and Brown, Christopher A. 1,
1997, Annals of the CIRP, Vol. 46, pp. 497-500.

International Journal of Basic and Applied Science Research (IJBASR)

Print ISSN: , Online ISSN: , Vo lu me 1, Nu mber 1, December, 2014