Experimental Investigation of the Effects of Process Parameters on Cutting Force in External Cylindrical Grinding

Abstract

Cutting force is a vital parameter that affects product quality. Proper control of the cutting force helps optimize the production process as it improves productivity and product quality. This paper assesses the influence of machining parameters, such as alloy steel hardness and workpiece diameters, to cutting forces when external cylindrical grinding by experimental methods. The cutting force was measured using a workpiece shaft-mounted sensor with a balanced bridge-type resistor sensor. Steel for testing: 40Cr, 9CrSi, 65Mn, and W18Cr4V, which were heat-treated at three different hardness levels: 40, 50, and 60 HRC. The Taguchi method's experimental results show that the main parameters affecting cutting forces are: Feed rate of the grinding wheel Sd, cutting depth t, and hardness of workpiece material on the HRC scale. Since then, we built a mathematical model of the normal cutting force function Fn and tangent cutting force function Ft according to Sd, t, and HRC of 9CrSi steel then tested again with three steel types: 40Cr, 65Mn, and W18Cr4V for quite similar results. The cutting force is controlled through cutting parameters suitable for different hardness and workpiece material based on this model.

Analysing the Impact of Cutting Force and Vibration on Surface Roughness in External Cylindrical Grinding of SKH2 Stell

“…However, due to the more significant influence of Sd and t compared to nw, the optimal grinding mode within this range of investigation is achieved with Sd = 0.3 mm/rev, t = 0.05 mm, and Nw ranging from 100 to 150 rpm. With the grinding parameters (2) Surface roughness (Ra) set as Sd = 0.3 mm/rev, t = 0.05 mm, and nw = 100 rpm, Fn = 6.22 N, Ft = 1.99 N, and A = 0.514 m/s 2 . After substituting these values into equation ( 2), the predicted surface roughness value is Ra = 0.308 µm.…”

“…The cutting force during the grinding of SKH2 steel with a hardness value of 60 HRC was investigated. Based on surveys of experimental ranges of grinding modes suitable for finish grinding [2]. The feed rate (Sd) was varied at three levels: 0.3, 0.4, and 0.5 mm/rev.…”

“…Cutting force can be broken down into three components [1]: axial force (Fa), which coincides with the toolpath; normal force (Fn), which prevents the penetration of abrasive particles into the material being cut and is perpendicular to the cutting surface of the grinding wheel; and tangential force (Ft), which acts on the grinding wheel surface. ______________ Prior research has explored aspects of the shear force problem, with one study using experimental design methods to measure normal and shear force while grinding the outer circle and developing a dependent relationship between cutting force and cutting mode [2]. Another study analysed wheel topography and grit force to model grinding [3].…”