Predictive Modelling and Analysis of Process Parameters on Material Removal Characteristics in Abrasive Belt Grinding Process

Vigneashwara Pandiyan,Gunasekaran Praveen,Wahyu Caesarendra,Tegoeh Tjahjowidodo

doi:10.3390/app7040363

Vigneashwara Pandiyan, Gunasekaran Praveen + Show 2 more

Open Access

https://doi.org/10.3390/app7040363

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Journal: Applied Sciences	Publication Date: Apr 6, 2017
Citations: 57	License type: CC BY 4.0

Affiliation: Nanyang Technological University

Abstract

The surface finishing and stock removal of complicated geometries is the principal objective for grinding with compliant abrasive tools. To understand and achieve optimum material removal in a tertiary finishing process such as Abrasive Belt Grinding, it is essential to look in more detail at the process parameters/variables that affect the stock removal rate. The process variables involved in a belt grinding process include the grit and abrasive type of grinding belt, belt speed, contact wheel hardness, serration, and grinding force. Changing these process variables will affect the performance of the process. The literature survey on belt grinding shows certain limited understanding of material removal on the process variables. Experimental trials were conducted based on the Taguchi Method to evaluate the influence of individual and interactive process variables. Analysis of variance (ANOVA) was employed to investigate the belt grinding characteristics on material removal. This research work describes a systematic approach to optimise process parameters to achieve the desired stock removal in a compliant Abrasive Belt Grinding process. Experimental study showed that the removed material from a surface due to the belt grinding process has a non-linear relationship with the process variables. In this paper, the Adaptive Neuro-Fuzzy Inference System (ANFIS) model is used to determine material removal. Compared with the experimental results, the model accurately predicts the stock removal. With further verification of the empirical model, a better understanding of the grinding parameters involved in material removal, particularly the influence of the individual process variables and their interaction, can be obtained.

Highlights

Abrasive grinding is a widely employed finishing process, with abrasive grains being used as the cutting edge to accomplish close tolerances and excellent dimensional correctness and surface integrity
Abrasive Belt Grinding is a modification of the traditional grinding processes in which the contact wheel is made of polymer backing material
We have proposed a process parameters on the process output and helps in predicting the significance of all factors and numerical model to predict material removal as a function of process parameters, namely, hardness, their interactions [11]

Summary

Introduction

Abrasive grinding is a widely employed finishing process, with abrasive grains being used as the cutting edge to accomplish close tolerances and excellent dimensional correctness and surface integrity. Abrasive Belt Grinding is a modification of the traditional grinding processes in which the contact wheel is made of polymer backing material. The soft contact polymer wheel enables this machining process to be appropriate to machine free-form surfaces due to its versatility, efficiency, and ability to machine workpieces of intricate shapes and geometry [1]. Understanding of such a process is one of the most delicate problems in the industry due to the high complexity and nonlinearity.

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