A study on the surface grinding process of the SUJ2 steel using CBN slotted grinding wheel

Abstract

Using slotted grinding wheel in machining is a new approach in grinding technology. The slotted grinding wheel is used to improve the introduction of cool lubricant into the cutting zone, improve chip release condition and heat release condition during machining, thereby facilitating to improve the efficiency of the grinding process. However, up to now, the studies that are performed using this type of grinding wheel is very limited. To contribute some results to this rather new research direction, in this article we present the grinding process of SUJ2 steel using CBN slotted grinding wheel. The orthogonal Taguchi matrix with nine experiments was used to design the experimental matrix with three input parameters including workpiece velocity, feed rate, and depth of cut. The output parameters that were used to evaluate the quality and effectiveness of the grinding process were surface roughness, system vibrations in X, Y, Z directions, and the material removal rate. In surface grinding process using CBN slotted grinding wheel, all three input parameters (workpiece velocity, feed rate, and depth of cut) have a significant influence on the surface roughness, vibration. In which, the feed rate has the most influence on the output parameters. The second factor that influenced on the output parameter was the depth of cut. The workpiece velocity has the smallest influence on the output parameters. Data Envelopment Analysis Based Ranking (DEAR) method was used to solve the multi-objective optimization problem in surface grinding process. By applying this method, the optimal value of input parameter that were determined to obtain the minimum values of surface roughness and system vibration components, and to obtain the maximum of material removal rate. The optimum values of input parameters were the workpiece velocity of 15 m/min, the feed rate of 4 mm/stroke, and cutting depth of 0.015 mm. DEAR method can be applied to improve the quality and the effectiveness of the grinding process by reducing the surface roughness and system vibration components and increasing the material removal rate.