Abstract
In this study, the mutil-objective optimization was applied for the surface grinding process of SAE420 steel. The aluminum oxide grinding wheels that were grooved by 15 grooves, 18 grooves, and 20 grooves were used in the experimental process. The Taguchi method was applied to design the experimental matrix. Four input parameters that were chosen for each experiment were the number of grooves in cylinder surface of grinding wheel, workpiece velocity, feed rate, and cutting depth. Four output parameters that were measured for each experimental were the machining surface roughness, the system vibrations in the three directions (X, Y, Z). The DEAR technique was applied to determine the values of the input parameters to obtaine the minimum values of machining surface roughness and vibrations in three directions. By using this technique, the optimum values of grinding wheel groove number, workpiece velocity, feed-rate, cutting depth were 18 grooves, 15 m/min, 2 mm/stroke, and 0.005 mm, respectively. The verified experimental was performed by using the optimum values of input parameters. The validation results of surface roughness and vibrations in X, Y, Z directions were 0.826 (µm), 0.531 (µm), 0.549 (µm), and 0. 646 (µm), respectively. These results were great improved in comparing to the normal experimental results. Taguchi method and DEAR technique can be applied to improve the quality of grinding surface and reduce the vibrations of the technology system to restrain the increasing of the cutting forces in the grinding process. Finally, the research direction was also proposed in this study
Highlights
Using a discontinuous grinding wheel was a promising solution in improving the efficiency of the grinding process [1, 2]
(2021), «EUREKA: Physics and Engineering» Number 1. The results from these figures showed that: – the number of grooves on the cylinder surface of grinding wheel had the most influence on the machining surface roughness
This issue can be explained that when the number of the grooves changes, it makes the changes of the friction between grinding wheel and workpiece surface. It changes the level of coolant introduction into the cutting zone and changes the chip release and heat release ability during machining. These factors change the degree of scratching of the grinding grains on the workpiece surface and change the plastic deformation on the workpiece surface, so changing the surface roughness; – the second factor that influenced on the machining surface roughness was workpiece velocity
Summary
Using a discontinuous grinding wheel (slotted and segmented wheel) was a promising solution in improving the efficiency of the grinding process [1, 2]. Using slotted grinding wheel could reduce the cutting heat by 40 % to 80 % compared with conventional grinding wheels [3]. Using segmented grinding wheel could reduce the cutting force by up to 30 % compared with conventional grinding wheels [4]. Some recommendations when using a slotted aluminum oxide grinding wheel have been proposed: surface roughness will have a minimum value when the number of grooves on the grinding wheel was (grooves) [7], the cutting force is minimized when the grooves in the grinding wheel were 20 (grooves) [8]. Research to find the solutions to (2021), «EUREKA: Physics and Engineering» Number 1 reduce surface roughness when grinding with conventional grinding wheel has been published in many studies. The studies that are performed to improve the surface quality when using the segmented grinding wheel for each different material were necessary
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