Cylindrical grinding - experimental investigation and Taguchi study of process parameters on EN31 and mild steel

Abstract

Cylindrical grinding, a secondary machining operation, a finishing operation in the manufacturing industry across the world. The volume of removed material over a given time (MRR) and quality of the surface (Roughness) obtained are the two important characteristics that investigated by researchers with respect to output responses from the process in understanding product quantity and quality. These two output parameters, any machining operation, are primarily important in consumer perspective vis-à-vis manufacturer. In this investigation, experiments are conducted and analyzed to arrive at the optimal grinding conditions/parameters in cylindrical grinding. The outcome of the machining will have a good surface quality by removing maximum material; confirming ovality and cylindricity of the specimen made from EN31 and Mild Steel. Taguchi DOE recommendations are considered in investigating the influence of input process parameters i.e. speed, feed, and depth of cut on machining outcome. Regression module in Minitab is used to apply a linear fit which is a general/simple recommendation for the parameters in order to understand the influence of these parameters on the expected outcome i.e., the maximum volume of material removed and to achieve a better surface finish with a minimum value of deviations in ovality (circularity) and cylindricity of the machined component by conducting experiments on a general-purpose cylindrical grinding machine.

Combining Taguchi method and DEAR method for multi-objective optimization of grinding process

“…For studying the optimization of the external cylindrical grinding process, to ensure the minimum surface roughness, the Taguchi method has been applied to design the experimental matrix, followed by the Signal-to-Noise ratio (S/N) to determine the optimal value of cutting speed, feed rate, and cutting depth when grinding EN-19 steel [7], when grinding 304 stainless steel [8], when grinding EN-31 steel and mild steel [9], when grinding EN-19 [10]; to determine the optimal value of cutting speed, feed rate, cutting depth and billet hardness when grinding EN-19 steel [11]; to determine the optimal value of cutting speed, workpiece speed, grain size, cutting depth, coolant flow, and grinding stroke number when grinding EN-47 steel [12]; to determine grain size, cutting depth and type of coolant when grinding Inconel 718 alloy [13]; to determine the value of cutting speed, workpiece speed, cutting depth, feed rate and grinding wheel material when grinding EN8 steel [14].…”

“…To ensure the minimum value of MRR, the Taguchi method and S/N ratio analysis method have also been applied to determine the optimal value of cutting speed and feed rate when grinding EN-31 steel and mild steel [9]; when grinding EN-19 steel [10], when grinding IS319 Brass [15], when grinding AISI 316 steel [16]; to determine the optimal value of cutting speed, workpiece speed, grain size, cutting depth, coolant flow, and grinding stroke number when grinding EN-47 steel [12]; when grinding EN21AM steel [17,18].…”