chapter 3 experimental detailsshodhganga.inflibnet.ac.in/bitstream/10603/11705/8/08_chapter...
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CHAPTER 3
EXPERIMENTAL DETAILS
In this chapter, the experimental set up, design of experiments,
method of analysis and experimental details are discussed.
3.1 EXPERIMENTAL SET UP
Belt grinding machine used for the optimisation studies is shown in
Figure 3.1. An abrasive belt grinding machine uses coated abrasive belt as a
grinding tool. It is used to evaluate the performance of the abrasive belts.
Figure 3.1 Autobelt evaluator – abrasive belt grinding machine
Idle
rollContact
wheel
Workpiece
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Machine details are given below,
Grinding machine : Automatic Belt Grinding
Machine (ABGM)
Maximum speed : 50 m/s
Maximum belt width and length : 50 mm and 750mm
Diameter of contact wheel : 300 mm
Loading control : Pressure
Figure 3.2 depicts the experimental set up. Abrasive belt is
mounted on the contact wheel, which is normally a rubber coated metal
wheel. Nearly homogenous pressure was given between the work piece and
belt. At the microscopic scale, the contact is localized within the peaks of
abrasive grains. Abrasive belt is driven through the contact wheel which is
attached to the motor. The motor has variable drive to change the RPM of the
contact wheel.
Figure 3.2 Schematic view of experimental setup
3.2 CONTACT WHEEL
The contact wheel is a rubber backing wheel used for mounting the
abrasive belt. Three different backing wheels are used for varying the
gripping force of the belt, namely 1:1, 1:2 and 1:3(land to groove ratio)
serrated wheels. Figure 3.3 clearly shows the land to groove ratio of the
Idler wheel
Abrasive belt
Contact wheelWork piece
Feed
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respective serrated wheels. The land area of the wheels are calculated based
on the surface speed of the wheel and mentioned as contact area (mm2/rev).
The contact area is related to the dimension of the work material, land area
and surface speed of the wheel.
Figure 3.3 Serrated contact wheels
3.3 MATERIALS SELECTION
Belt grinding is used to grind variety of materials for different
applications. Applicable materials from industries and literature are stainless
steel, cast iron, wood, alloyed steel and tool steel. Stain less steel is widely
used in food processing, and chemical industries as material for structural,
equipments and containers. Mostly sheets and pipe form with mirror finish.
Hence stainless steel was used as a work material for all the studies. A
medium carbon steel and tool steel were used for selected experiments. Apart
from metals, belt grinding is also used to finish brittle materials such as
marble, granite and alumina. Among the three materials, alumina is used as
engineering material. Hence Alumina has been chosen for optimization
studies. Metallic specimens like AISI 304 stainless steel, EN8 steel and High
carbon and High chromium steel were used for different experiments. The
properties of the work materials used in the present research work are given
below.
Land Groove:
1: 3 serrated 1: 2 serrated
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AISI304 stainless steel
AISI 304 stainless steel materials of same heat number were
procured. The chemical composition of the material was found to be
Ni- 8.8%, Cr-19.8%, C-0.08% and Mn of 1.5%. The hardness of the material
is 30HRC.
EN8 stainless steel
EN8 steel of same heat number was procured in the form of rods of
diameter 30mm diameter with length of 300mm. The chemical compositions
of the material are C-0.4%, Si-0.25%, S- 0.015% and P- 0.015%. The
hardness of the material is 45HRC.
HCHCr steel
HCHCr steel materials was procured in the heat treated conditions.
The hardness of the material was 60 to 65 HRC. The typical chemical
composition of the material was C-2.2%, Mn-0.52%, Cr-12.2%, Si-0.5%, V-
0.69% and W-0.64%
Alumina ceramics
The work materials taken for this research are alumina ceramics
(Al2O3) of three different purity levels (90%, 92% and 94% pure alumina)
manufactured by Carborundum Universal. The specimens are in the form of
hollow tubes having dimensions of external diameter 30mm, 5mm wall
thickness and 100mm in length. The Al2O3 has the grain size, ranging from 2–
10 m. Figure 3.4 shows the typical samples of the alumina ceramic materials
used for this study. Density of the materials are 3.6, 3.65 and
3.7 gm/cm3
, for 90, 92 and 94% purity respectively. The compressive
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strengths are 1700, 1800 and 2000 MPa for the 90, 92 and 94% purity
respectively.
Figure 3.4 Alumina ceramic Specimen
3.4 OUTPUT PARAMETERS MEASURED
From the literature review, it is evident that belt wear of the
abrasive belt grinding reflects the tool wear on the whole. Therefore, in the
present study, abrasive belt wear was considered as direct indicator of tool
status. For each experiment, material removal was measured interms of
weight loss. A fresh work piece was used for grinding purpose. The size of
the workpiece used for the each experiment was kept constant to avoid the
variation in the application of grinding pressure. Wherever required the
surface finish of the work piece was measured at the end of the testing
processes. Depending on the type of studies, belt wear and material removal
were measured periodically for every two minutes. A detailed fractographic
study on worn out belts was carried out to understand the mechanism of tool
wear. Table 3.1 shows the output process parameters and methodology of
measurements to analyze the performance of grinding.
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Table 3.1 Methodology for Measuring the Output Parameters
S.NoOutput process
parametersMeasuring methodology
1. Material removal
By weighing the work piece before and
after grinding using electronic weighing
machine with accuracy of 0.01 gm.
2. Abrasive Wear
By weighing the belt before and after
grinding using electronic weighing
machine with accuracy of 0.01 gm
3. Surface RoughnessMeasured using Surfcoder(SE3500), a
stylus based surface roughness tester
3.5 GRINDING PARAMETERS
Abrasive belt grinding is relatively a complex process with large
number of interacting variables, which varies depending upon application. In
this research work the following factors are considered for the optimization,
Belt characteristics - bonding system, backing material, Abrasive
grit size, Flexing pattern
Operating conditions - Belt speed, grinding pressure, contact area
and coolant.
For optimization of the belt grinding process, operating parameters
are often determined with the aid of grinding tests. If more number of
parameters is there then, the conventional testing method becomes time
consuming process. Hence Taguchi methods of design of experiments are
used to select the significant grinding parameters.
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3.6 DESIGN OF EXPERIMENTS AND ANALYSIS OF DATA
3.6.1 Design of Experiments
Taguchi Experimental Design (TED) was used to find out the
influence of the experimental factors and their significance on the response.
Taguchi method uses signal-to-noise (S/N) ratio, value to interpret the
experimental results data and the evaluation of characteristics for desired
parameter settings (Rose, 1996). This is because the S/N ratio can reflect both
average and variation of the quality characteristics. Depending on the quality
characteristics involved, different S/N ratios may be applicable, including
smaller is better (SB), nominal is the best (NB), or greater is better (GB).
Regardless of the category of the performance characteristic, normally the
greater S/N ratio corresponds to the better performance characteristics.
Therefore, the best level of the factors is mostly the level with the highest S/N
ratio.
3.6.2 Application of Taguchi Method
The various steps in the application of the Taguchi method in the
present study are as follows;
Selection of the factors and their levels
The grinding parameters such as contact area, belt speed and
grinding pressure are, generally controllable in any grinding situation,
selected as factors for study. Factors such as bonding system, flexing, and
backing are available to the maximum of three levels of variants. Hence three
levels are selected for each factor, to study the non –linearity effects.
Selection of Orthogonal Array and assignment of factors
To conduct an optimization study a special set of arrays called
orthogonal arrays needs to be selected. These standard arrays stipulate the
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way of conducting the minimal number of experiments which could give the
full information of all the factors that affect the performance parameter.
Orthogonal Array (OA)
Orthogonal Arrays are a set of tables of numbers created by
Taguchi that allow experimenters to study the effect of a large number of
control and noise factors on the quality characteristics with a minimum
number of trials ( Law and Kelton 2000). The choice of OA depends on the
number of factors to be studied for optimization, number of interactions to be
examined, number of levels required for each factor.
The number of degrees of freedom for the OA should be greater
than or equal to the degrees of freedom required for studying the main and
interaction effects.
Minimum Number of experiments
or = ( No. of level-1) X No. of factors +1
Degrees of freedom for the study
Further to selection of appropriate OA the factors are assigned to
various columns of the array and subsequent interaction columns located. For
example, in an experiment with three factors and three levels, the degree of
freedom is 9 hence an L9 orthogonal array shall be chosen for the studies.
Table 3.2 shows typical orthogonal array of L9.
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Table 3.2 Orthogonal array
Vairable 1 Variable2 Variable3
1 1 1 1 p1
2 1 2 2 p2
3 1 3 3 p3
4 2 1 2 p4
5 2 2 3 p5
6 2 3 1 p6
7 3 1 3 p7
8 3 2 1 p8
9 3 3 2 p9
L9 (34) Orthogonal array
ExperimentIndependent variables
Performance
parameter value
The orthogonal arrays have the following special properties that
reduce the number of experiments to be conducted.
1. The vertical column under each independent variables of the
above table has a special combination of level settings. All the
level settings appear an equal number of times. For L9 array
under variable 3, level 1, level 2 and level 3 appears thrice.
This is called the balancing property of orthogonal arrays.
2. All the level values of independent variables are used for
conducting the experiments.
3. The sequence of level values for conducting the experiments
shall not be changed. This means one can not conduct
experiment 1 with variable 1, level 2 setup and experiment 4
with variable 1, level 1 setup. The reason for this is that the
arrays of each factor columns are mutually orthogonal to any
other column of level values. The inner product of vectors
corresponding to weights is zero. If the above 3 levels are
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normalized between -1 and 1, then the weighing factors for
level 1, level 2 , level 3 are -1 , 0 , 1 respectively. Hence the
inner product of weighing factors of independent variable 1
and independent variable 3 would be
(-1 * -1+-1*0+-1*1)+(0*0+0*1+0*-1)+(1*0+1*1+1*-1)=0
3.6.3 Analysis of Results
Experiments are conducted on random sequence to avoid any
unknown and uncontrolled factors that may vary during the entire experiment
and which may influence the results. Each experiment is repeated for three
times and average results taken up for analysis. The results of the experiments
were calculated for based on the following types of quality characteristics.
Evaluation of S/N ratios
Taguchi suggests the transformation of the data in a trial in to a
consolidated single value called S/N ratio. Here, the term ‘signal’ represents
the desirable value (mean) and the ‘noise’ represents the undesirable value
(standard deviation). Hence the S/N ratio represents the amount of variation
present in the out put. Depending upon the objective of the output, S/N ratios
are calculated in the following form
Smaller-the-better
Smaller-the-better characteristic is a non-negative measurable
characteristic that has an ideal state or target of zero. This is used to measure
characteristics such as belt wear and surface finish. Formula to calculate
smaller that better S/N ratio ( ) is
n2
i
i 1
10 Log y /n
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Larger-the-better
Larger-the-better characteristic is a non-negative measurable
characteristic that has an ideal state or target of infinity. This measures
characteristics such as material removal G-ratio and strength. Formula to
calculate larger the better S/N ratio ( ) is
n2
i
i 1
10 Log (1 / y ) x 1/n
where yi the measured output for the ith
experiment and n the number of
experiment in a trial.
3.6.4 Sequence of Analysis
Results of the experiments were analyzed in three stages namely
1. Level average response analysis based on Factor effect
diagram and Average signal to noise ratio.
2. Analysis of variance (ANOVA) based on Average S/N ratios.
3. Multiple regression analysis based on experimental results.
Factor effect diagram
The level average response analysis is based average on S/N data.
The analysis is done by averaging the S/N data at each level of each factor
and plotting the values in a graphical form called factor effect diagram. The
level average response plots based on S/N data help in optimizing the
objective function under study. The peak points in these plots correspond to
the optimum condition. From the plot the influence of individual factors and
its level are analyzed, based on the slope of the curve. The absolute difference
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between the average S/N ratio values of the two levels reveals the effect of
each factor. The larger the difference, the stronger is the influence to the
performance.
ANOVA and modeling of responses
ANOVA is a computational technique to estimate quantitatively the
relative contribution of each controlled parameter makes in the overall
measured response. An Analysis of Variance (ANOVA) is performed on S/N
ratios to obtain the contribution of each of the factor. This is performed by
separating the total variability of the response performance, which are
measured by the sum of the squared deviations from the total mean of the
response performance and into contributions by each of the factors under
investigations and the error.
When the saturated design type is chosen, where all columns in OA
are assigned with the factors; the variation due to error is estimated by
pooling the factors having less influence for correct interpretation of results.
By comparing the sum of squares values of each factor with the factor that has
the highest sum of squares, which is less than 10% or lower than the most
influential factor, then these factors are considered insignificant (Roy 2001).
Fisher test (F-test) factor for 90% confidence level also used to find out the
significant factor. ANOVA was calculated for all the out put.
Multiple non linear regressions
A multiple regression method was performed using a non-linear fit
between the response and the factors. Based on the observed results of the
trials, a mathematical equation was formulated using the multiple regression
method by using a non-linear fit between the response and the significant
parameters.
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Multiple regression analysis is practical and relatively easy for use
and widely used for analyzing experimental results. By using this method the
influence of individual parameters were defined in equation. In regression
equation apart from significant parameters, other factors are also considered.
The following mathematical models were formulated for all measured
performance.
Material Removal = K1.Sw
1.Rx1.A
y1.C
z1 (3.1)
Belt wear = K2.Sw
2.Rx2.A
y2.C
z2 (3.2)
G-Ratio = K3.Sw
3.Rx3.A
y3.C
z3 (3.3)
Surface finish = K3.Sw
3.Rx3.A
y3.C
z3 (3.4)
where K, w, x, y, z are constants and S, R, A and C are grinding variables
such as Belt Speed (S) (m/s), Rotation of the work piece (E) (rpm), Density of
Alumina (D) (g/cm3)., Contact area(C) (mm
2/rev), abrasive grit size (G) (no),
flexibility (F) (mg) and peel strength (B) (N/mm). The suitable variables are
used depends up on the design of experiment. Regression coefficient is
calculated for the each regression equation which is represented as R2 = 1 -
Residual SS / Corrected SS, where SS- sum of square. Higher the value of
regression coefficient means the effective correlation of non linear fit with
actual results.
Validation of findings
Confirmatory run was conducted for further analysis. The optimum
level of the each factors are performed as a validation test. The test results are
compared with values derived from the non linear fit.
Figure 3.5 shows the sequence of analysis followed in this work.
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Figure 3.5 Sequence Analysis
3.7 VARIABLE PARAMETERS
The following belt properties and machine variables were used in
the studies.
Identification of Quality characteristics (performance
measure)
Selection of factors and its levels
Select Orthogonal Array (OA)and assign the factors and its
levels to the OA
Analysis of experimental data using signal to noise ratio,
factor effect diagram and optimum levels
Apply ANOVA to identify the significant factors
Form multiple non linear Regression Equation
Verification of the optimal design parameters through
confirmation experiment and compare the values
calculated from regression equation
Conclude on influence of the factors
Conduct the test described by the trials in the OA
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1. Belt speed (m/sec) : 38, 41 and 44.
2. Rotation of the (specific to alumina grinding)
Workpiece (rpm) : 720, 840, and 960
3. Material : AISI 304 Stainless steel, EN8 Steel
HCHCr steel and alumina
4. Contact wheel serration : 1:1, 1:2 and 1:3 (land to groove ratio)
5. Flexing pattern : 900, 90
0+45
0and 90
0 +45
0-45
0
6. Grinding pressure (bar) : 0.5, 1.0 and 1.5
7. Bonding system : Resin over resin, resin over glue, and
glue over glue
8. Backing material : Cotton, polycot and polyester
3.8 EXPERIMENT DETAILS
The study is conducted in two phases. The first phase of five set of
experiments are conducted to select the belt and machine parameters which
have strong influence on the output.
In second phase optimization of belt grinding of alumina ceramics
and stainless steel has been carried out. Taguchi method is used in the
selection of process of strongly influencing, belt and machining parameters.
For optimization of belt grinding of stainless steel, was done with full
factorials to validate the findings of phase I study. Optimization study was
done for Alumina ceramic as per taguchi approach. The design of experiments
for different set of factors and levels is shown in Tables 3.3 - 3.15.
Experiment 1 - Effect of bonding system in abrasive belt grinding
Bonding system - The purpose of bonding system is to hold the
grains and backing material together. Among the three kinds of bonding
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system discussed in section 1.2.3, it is required to understand and select the
suitable bonding system for further studies. The strength of bond is measured
as peel strength. Peel strength is defined as an ability of the material to resist
forces that can pull it apart by separating a coated layer from the backing
material. Peel strength, belt speed and pressure are chosen as the factors in
this experiment. Peel strength of glue over glue, resin over glue and resin over
resin are 40, 50 and 65 N/mm respectively. The adhesive strength is
considered as the parametric value for the discussion.
Abrasive belt: Abrasive – Alumina, Grit number- 60, Workpiece –
stainless steel
Table 3.3 Bonding system and machining parameters
S.No Parameter unit Level 1 Level 2 Level 3
1 Bonding system -Peel strength N/mm 40 50 65
2 Speed m/s 38 41 44
3 Pressure bar 0.50 1.0 1.5
Table 3.4 Orthogonal array for the experiment 1
Ex.no Bonding systemBelt Speed
(m/s)
Grinding
pressure
(bar)
1 Glue over glue 38 0.5
2 Glue over glue 41 1.0
3 Glue over glue 44 1.5
4 Resin over glue 38 1.0
5 Resin over glue 41 1.5
6 Resin over glue 44 0.5
7 Resin over resin 38 1.5
8 Resin over resin 41 0.5
9 Resin over resin 44 1.0
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Experiment 2 Effect of backing material in abrasive belt grinding
Backing material - The backing materials (section 1.2.4) posses
having different kind of properties based on the yarn. Physical properties of
the belt vary with respect to type of backing material. The mechanical
properties such as tensile strength, stretch (elongation) and stiffness of the belt
were measured. The stretches of the belts at 590 N are 7mm, 10mm and 14
mm respectively for polyester, polycot and cotton. Each experiment was
performed until the grain was pulled out from the belt. Belt was visually
examined for every tow minutes for any grain shedding.
Abrasive belt used : Abrasive – Alumina, Grit number-60 and
Bonding system – Resin over resin. Work material- AISI 304SS.
Table 3.5 Backing materials and machining parameters
S.No Parameter Unit Level 1 Level 2 Level 3
1 Type of backing-stretch mm 7 10 14
2 Speed m/s 38 41 44
3 Pressure Bar 0.50 1.0 1.5
Table 3.6 Orthogonal array for the experiment 2
Ex.noBacking
material
Belt
Speed
(m/s)
Grinding
pressure
(bar)
1 Polycot 38 0.5
2 Polycot 41 1.0
3 Polycot 44 1.5
4 Polyester 38 1.0
5 Polyester 41 1.5
6 Polyester 44 0.5
7 Cotton 38 1.5
8 Cotton 41 0.5
9 Cotton 44 1.0
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Experiment 3 - Effect of abrasive grit on abrasive belt grinding
Abrasive grit size – Theoretic the size of abrasive has strong
influence in the grinding output. In order to understand the intensity of the
influence along with the machine parameters, grit size and contact areas are
considered as one of the factor.
Abrasive belt: Abrasive- Alumina, Bonding system- Resin over
resin, Backing materials – polyester. Work piece-AISI304 SS, EN8 and
HCHCr
Table 3.7 Abrasive grit and machining parameters
S.No Parameter Unit Level 1 Level 2 Level 3
1 Contact area mm2/rev 4210 2826 2120
2 Abrasive grit number 24 36 60
3 Speed m/s 38 41 44
4 Pressure bar 0.50 1.0 1.5
Table 3.8 Orthogonal array for experiment 3.
Ex.noContact Wheel
(mm2/rev)
Abrasive
grit
Belt Speed
(m/s)
Grinding
pressure (bar)
1 4210 24 38 0.5
2 4210 36 41 1.0
3 4210 60 44 1.5
4 2826 24 41 1.5
5 2826 36 44 0.5
6 2826 60 38 1.0
7 2120 24 44 1.0
8 2120 36 38 0.5
9 2120 60 41 1.5
The experiment was repeated for all the Workpieces.
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Experiment 4 - Effect of flexing pattern on belt grinding.
Flexing pattern - Flexing is the process to achieve the required and
uniform flexibility of coated abrasive belt. The hardened and rigid bond is
partially broken in a controlled manner in small area sections. Flexing is a
mechanical operation designed to break the adhesive bond at closely spaced,
predicted intervals. Mechanical flexing is capable of producing different
‘degrees’ of flexibility by varying the spacing between ‘breaks’, angle of the
break and number of flexing directions.
The flexing operation offers a degree of flexibility for coated
abrasive belts. A single flex (90o
degree) produces flex breaks perpendicular
to the grind direction. It is chosen where conformability is required in the
crosswise direction. Double flexing (45o
degree) produces a crosshatch of the
breaks that are 45o
degrees to the belt direction. A double flex adds moderate
conformability in all directions to the belt. Fully or triple (Figure 4.23) flexed
(90o+45
o-45
odegree) abrasives are combinations of single and double flexed.
The stiffness of the flexed belt differs with respect to type of flexing. The
schematic (Figure 3.5) of 90o , 90
o + 45
o and 90
o + 45
o- 45
o show the
flexing pattern in the belts. . The stiffness of different flexed 90o, 90
o +45
o
and 90o +45
o- 45
o are 220g, 195 g and 180 g respectively
Figure 3.5 Types of flexing
(a) 90o
(b) 90o+45
o( c ) 90
o +45
o-45
o
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Abrasive-alumina; Grit number-60, Bonding system- Resin over resin,
Backing materials – Polyester. Work piece- AISI304SS. The parameters
observed as the most significant grit 60, resin over resin and polyester
backing are chosen as parameters for the present study.
Table 3.9 Flexing and machining parameters
S.No Parameter Unit Level 1 Level 2 Level 3
1 Flexing degree 90 90+45 90+45-45
2 Speed m/s 38 41 44
3 Pressure bar 0.50 1.0 1.5
4 Contact area mm2/rev 4210 2826 2120
Table 3.10 Orthogonal array for Experiment 4
Ex.noFlexing
(degree)
Belt Speed
(m/s)
Grinding
pressure
(bar)
Contact Wheel
(mm2/rev)
1 90 38 0.5 4210
2 90 41 1.0 2826
3 90 44 1.5 2120
4 90+45 38 1.0 2120
5 90+45 41 1.5 4210
6 90+45 44 0.5 2826
7 90+45-45 38 1.5 2826
8 90+45-45 41 0.5 2120
9 90+45-45 44 1.0 4210
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Experiment 5 – Effect of coolant in belt grinding
Grinding coolant – Grinding is also influenced by the external
factors such as grinding environment. The effect of the coolants such as water
and oil based coolant need to be compared with dry grinding to understand
the effect of coolants in the belt grinding, hence above coolants are
considered as factors.
Abrasive- alumina; Grit number- 60; Work piece – AISI 306SS
Table 3.11 Coolant and machining parameters
S.No Parameter Unit Level 1 Level 2 Level 3
1 coolant Dry water Oil
2 Belt speed m/s 38 41 44
3 Grinding pressure Bar 0.50 1.0 1.5
4 Contact area mm2/rev 4210 2826 2120
Table 3.12 Orthogonal array for experiment 5
Belt SpeedG rinding
pressureContact area
m /s bar m m2/rev
1 Dry 38.00 0.50 4210
2 Dry 41.00 1.00 2826
3 Dry 44.00 1.50 2120
4 W ater 38.00 1.00 2120
5 W ater 41.00 1.50 4210
6 W ater 44.00 0.50 2826
7 Oil 38.00 1.50 2826
8 Oil 41.00 0.50 2120
9 Oil 44.00 1.00 4210
Ex.no Coolant
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Experiment 6 - Optimization of belt grinding of Alumina ceramics
Alumina ceramics with different purity level was used as work
material. In grinding of alumina ceramics, silicon carbide abrasive was used
as per Abrasive index. Initial trials with constant pressure resulted in more
chipping of work material. In order to avoid chipping, belt grinding was done
with constant feed rate and work piece rotation.
Abrasive - Silicon carbide; Bonding system – Resin over resin,
Backing materials – Polyester, Flexing pattern – 900 ,Grit number - 60; feed
rate - 0.80mm/minute.
Table 3.13 Material and Machining parameters
S.No Parameter Unit Level 1 Level 2 Level 3
1 Speed m/s 38 41 44
2 Rotation RPM 720 840 920
3 Material % of alumina 90 92 94
4 Contact area mm2/rev 4210 2826 2120
Table 3.14 Orthogonal array for experiment 6
Ex.noBelt Speed
m/s
Work piece
Rotation
rpm
Density of
Alumina
(g/cm3)
Contact area
mm2/rev
1 38 720 3.60 4210
2 38 840 3.65 2826
3 38 960 3.70 2120
4 41 720 3.65 2120
5 41 840 3.70 4210
6 41 960 3.60 2826
7 44 720 3.70 2826
8 44 840 3.60 2120
9 44 960 3.65 4210
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Experiment 7 – Optimization of belt grinding of stainless steel
For Optimization of machining parameters, full factorial
experiments were conducted. The most significant machining parameters
factors from the experiments 1 to 6 were used as the parameters. Abrasive belt
made with Alumina grit size of 60 is used. Machining parameters like belt
speed, contact area and grinding pressure are used as variables.
Table 3.15 Full factorial Experiments
Belt SpeedGrinding
pressureContact area
1 38 0.5 4210
2 41 0.5 4210
3 44 0.5 4210
4 38 1.0 4210
5 41 1.0 4210
6 44 1.0 4210
7 38 1.5 4210
8 41 1.5 4210
9 44 1.5 4210
10 38 0.5 2826
11 41 0.5 2826
12 44 0.5 2826
13 38 1.0 2826
14 41 1.0 2826
15 44 1.0 2826
16 38 1.5 2826
17 41 1.5 2826
18 44 1.5 2826
19 38 0.5 2120
20 41 0.5 2120
21 44 0.5 2120
22 38 1.0 2120
23 41 1.0 2120
24 44 1.0 2120
25 38 1.5 2120
26 41 1.5 2120
27 44 1.5 2120
Exp.no
m /s bar mm2/rev