ISSN (Online) 2581-9429 IJAR SCT ISSN (Print) 2581-XXXX

International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 11, Issue 2, November 2020 Impact Factor: 4.819

Experimental Analysis of a by Increasing Multiple Passes in Dressing Mohammed Abdul Kadar1, Elanchezhian J2 and Kalaimagal S3 Assistant Professor, Department of Mechanical Engineering Anand Institute of Higher Technology, Chennai, India1,2 Assistant Professor, Department of Mechanical Engineering Anna University (CEG Campus), Chennai, India3

Abstract: When sharpness of grinding wheel becomes dull, a dressing is an operation performed because of glazing and loading, dulled grains and chips are removed (crushed or fallen) with a proper dressing tool to make sharp cutting edges and simultaneously, make recesses for chips by properly extruding to grain cutting edges. The basic dressing operation consists of removal of grains and swarfloaded, generation and exposure of the new cutting edges on the cutting surface of the grinding wheel. The former is obtained by digging out the swarf and the latter is achieved by fracturing the existing grains and allowing desired protrusion of abrasive particles on the cutting surface. Both of the above operations are carried out using a diamond dresser (3 carat). A part of this work focuses on finding the optimum dressing parameters (depth of cut of the dresser and the number of passes) which gives optimum cutting condition for grinding using conventional method of grinding using diamond dresser, Water Jet Machine and Abrasive Water Jet Machine. The trial run on the conventional machine with different parameters was performed. The results obtained prove the possibility of using directly in the industrial practices.

Keywords: Conventional method, Dressing, Grains, Swarf, Grinding wheel, Diamond dresser. . I. INTRODUCTION The principle of dressing is demonstrated. It is achieved by fracturing the existing abrasive grains and allowing desired protrusion of abrasive particles on the surface. The operation also unloads the grinding wheel i.e. removes work piece material that is embedded on wheel surface after the grinding operation. On performing this operation, the wheel can machine again with higher feed and in- feed (depth of cut) rate, which permits to conclude the machining in less time but with higher accuracy. Dressing is required at regular intervals to maintain the desired grain edge sharpness and the grain protrusion. Grinding wheel loading is a process of accumulation of ground chips in the grit spacing. Proper monitoring of wheel loading is important to find the proper dressing time. Hence a low cost condition monitoring is need of the hour. In this work two such systems were developed. They are infrared monitoring technique and magnetic field technique. In the precision grinding operation, exacting tolerances and finishes often require careful control of the geometry and surface roughness of the wheel. In order to regenerate the wheel face, the wheel is trued and dressed. With awareness in people and advancement in manufacturing technologies, there is a huge demand for precision products. Grinding is a technique often used to manufacture the products with precision and quality. The performance of grinding operation significantly depends on the nature of grinding wheel and morphology of the abrasive grits used. The nature of grinding mechanisms such as cutting, ploughing and rubbing depends upon these parameters. Particularly, the grit size and the dressing parameters such as dressing lead, dressing depth, dressing tool profile decides the actual grinding process mechanisms along with the kinematic conditions during the grinding. Moreover, the structure of the grinding wheel can be controlled by dressing operation, which plays a dominant role in material removal rate and surface finish.

Copyright to IJARCST DOI: 10.48175/IJARSCT-631 203 www.ijarsct.co.in ISSN (Online) 2581-9429 IJAR SCT ISSN (Print) 2581-XXXX

International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 11, Issue 2, November 2020 Impact Factor: 4.819

II. MATERIALS AND METHODS Grinding is an abrasive machining process that uses a grinding wheel as the cutting tool. Grinding practice is a large and diverse area of manufacturing and tool making. It can produce very fine finishes and very accurate dimensions; yet in mass production contexts it can also rough out large volumes of metal quite rapidly. It is usually better suited to the machining of very hard materials than is "regular" machining. Grinding is the most common form of abrasive machining. It is a material cutting process which engages an abrasive tool whose cutting elements are grains of abrasive material known as grit. These grits are characterized by sharp cutting points, high hot hardness, and chemical stability and wear resistance. The grits are held together by a suitable bonding material to give shape of an abrasive tool. Figure1 illustrates the cutting action of abrasive grits of disc type grinding wheel similar to cutting action of teeth of the cutter in slab . Grinding wheel consists of hard abrasive grains called grits, which perform the cutting or material removal, held in the weak bonding matrix. A grinding wheel commonly identified by the type of the abrasive material used. The conventional wheels include aluminum oxide and silicon carbide wheels while diamond and CBN (cubic boron nitride) wheels fall in the category of super abrasive wheel.

Figure 1: Cutting Actions of Abrasive Grains

A) Trail Run to Check Loaded Grinding Wheel In the conventional machine process, the small grits used to loaded in the grinding wheel while machining the . This grits will be loaded for a period of time then swarf makes the grinding wheel as blur. The continuous loading of grits in the grinding wheel makes the irregular surface finish. To get a good surface finish, the grinding wheel has to be sharped, this process is called the dressing which is done by a diamond dresser. The dressing point of the diamond dresser is 3 carat. In the manufacturing industries, the dressing will be done for 0.2 mm with a single pass of the grinding wheel while the research has made increase in the number of passes to get more accuracy in the sharpness of the grinding wheel to achieve good results in the surface finish of the workpiece. is used to produce a smooth finish on flat surfaces. It is a widely used abrasive machining process in which a spinning wheel covered in rough particles (grinding wheel) cuts chips of metallic or nonmetallic substance from a workpiece, making a face of it flat or smooth.Surface grinding is the most common of the grinding operations. It is a finishing process that uses a rotating abrasive wheel to smooth the flat surface of metallic or nonmetallic materials to give them a more refined look by removing the oxide layer and impurities on work piece surfaces. This will also attain a desired surface for a functional purpose.

Copyright to IJARCST DOI: 10.48175/IJARSCT-631 204 www.ijarsct.co.in ISSN (Online) 2581-9429 IJAR SCT ISSN (Print) 2581-XXXX

International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 11, Issue 2, November 2020 Impact Factor: 4.819

Figure 2: Grinding Process of the Conventional Machining Process In this trial run, a newly brought grinding wheel was weighted show 2.459kg to know whether the wheel is loaded or not as shown in Figure 3. The grinding wheel has been fixed in the surface and made the machine to run for 30 min by giving 0.001 mm depth of cut for every pass of the magnetic bed of the surface grinding machine. Typical workpiece materials include cast iron and mild steel. These two materials don't tend to clog the grinding wheel while being processed. Other materials are aluminum, stainless steel, brass and some plastics. When grinding at high temperatures, the material tends to become weakened and is more inclined to corrode.

Figure 3: No Load Grinding Wheel After 30 min of trial run, the grinding wheel weight has been calculated again to confirm the status of grits loading in the grinding wheel. The Figure 4 clearly shows that the grits of the workpiece has been loaded around 2.481 kg which is 22 g in the grinding wheel.

Figure 4: Partially Loaded Grinding Wheel Copyright to IJARCST DOI: 10.48175/IJARSCT-631 205 www.ijarsct.co.in ISSN (Online) 2581-9429 IJAR SCT ISSN (Print) 2581-XXXX

International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 11, Issue 2, November 2020 Impact Factor: 4.819

In this trail run, the machine is made to run upto 1 hr with a continuous pass of 0.001 mm of depth of cut. Then the weight has been displayed as 2.498 kg as shown in Figure 5, which is 17 g of grits has been loaded in the grinding wheel.

Figure 5: Fully Loaded Grinding Wheel

III. RESULTS AND DISCUSSION The surface roughness has been measured in the 10 different spot (A–J) of the workpiece to check the grastic variation, before and after dressing process. The Figure 6, Spots of measuring Surface Roughness of the workpiece.This can also result in a loss of magnetism in materials where this is applicable.

Figure 6: Spots of measuring Surface Roughness Values of the workpiece

A) Experiment 01

 Wheel – Al2O3  Workpiece – HCHCr Steel  Dressing depth of cut – 0.2mm  No. of pass – 01  Length of cut – 25mm  Value for fully loaded wheel (µm) A B C D E F G H I J

4.31 4.09 4.22 4.00 3.82 4.17 4.01 3.99 3.78 4.29 Table 1: Roughness Value (µm) Before Dressing Roughness value after dressing and machining for 5 min. After 30 min of trial run, the grinding wheel weight has been calculated again to confirm the status of grits loading in the grinding wheel.

Copyright to IJARCST DOI: 10.48175/IJARSCT-631 206 www.ijarsct.co.in ISSN (Online) 2581-9429 IJAR SCT ISSN (Print) 2581-XXXX

International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 11, Issue 2, November 2020 Impact Factor: 4.819

A B C D E F G H I J

2.94 3.00 2.89 2.71 2.63 2.08 2.12 2.44 2.36 2.95 Table 2: Roughness Value (µm) After Dressing and Machining for 5 minutes

B) Experiment 02

 Wheel – Al2O3(Coarse)  Workpiece – HCHCr Steel  Dressing depth of cut – 0.1mm  No. of pass – 02  Length of cut – 25mm  Value for fully loaded wheel (µm)

A B C D E F G H I J

3.87 3.78 3.39 3.11 2.98 3.07 4.00 3.87 3.27 2.95 Table 3: Roughness Value (µm) Before Dressing Roughness value after dressing and machining for 5 min

A B C D E F G H I J

2.86 2.93 2.60 2.58 2.33 2.41 3.00 2.67 2.54 2.11 Table 4: Roughness Value (µm) After Dressing and Machining for 5 minutes

C) Experiment 03

 Wheel – Al2O3 (Coarse)  Workpiece – HCHCr Steel  Dressing depth of cut – 0.1mm  No. of pass – 02  Length of cut – 25mm  value for fully loaded wheel (µm)

A B C D E F G H I J

4.08 3.86 3.32 3.11 3.89 4.11 4.00 3.87 3.43 3.22 Table 5: Roughness Value (µm) Before Dressing Roughness value after dressing and machining for 5 min (µm)

A B C D E F G H I J

1.67 1.49 1.43 1.36 1.84 1.67 1.83 1.91 1.31 1.24 Table 6: Roughness Value (µm) After Dressing and Machining for 5 minutes

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International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 11, Issue 2, November 2020 Impact Factor: 4.819

B) Comparison of Roughness Values Surface roughness measurement to find optimum dressing parameter. The roughness value before dressing and machining has been compared in Table VII and Graph1. This they have made an in- process dressing maintains consistent wheel sharpness and reduces the heat generated during machining. It describes a systematic approach in deciding a proper dressing interval and an optimal dressing depth for the working of grinding wheel. The recent trends reveal the evolution of the surface roughness of the workpiece has been continuously observed during the grinding process and the wheel gets worn out. The roughness evolution is then related to different process parameters such as the dressing variables, the grinding ambience, the grinding forces and the radial wear of the wheel. EXPERIMENT 1 – FULLY LOADED WHEEL A B C D E F G H I J 4.31 4.09 4.22 4.00 3.82 4.17 4.01 3.99 3.78 4.29 EXPERIMENT 2 – PARTIALLY LOADED WHEEL A B C D E F G H I J 3.87 3.78 3.39 3.11 2.98 3.07 4.00 3.87 3.27 2.95 EXPERIMENT 3 – PARTIALLY LOADED WHEEL A B C D E F G H I J 4.08 3.86 3.32 3.11 3.89 4.11 4.00 3.87 3.43 3.22 Table 7: Roughness Value (µm) Before Dressing

ROUGHNESS VALUE BEFORE DRESSING

5.00 4.50 4.00 3.50 3.00 2.50 Exp1 2.00 Exp2 1.50 Exp3 1.00 0.50 0.00 A B C D E F G H I J LOCATION OF Ra MEASURED

Graph 1: Comparison of Roughness Values Before Dressing The Graph 1 clearly indicates the Roughness values of all the three experiments which is mentioned the above tables. The roughness value after dressing and machining for 5 min has been compared in Table VIII and Graph2. The roughness value obtained after 2 hours of machining is in medium range. The relevant gauss value obtained can be correlated to predict the roughness value during online monitoring.  It can also be inferred that there is no saturation in the field strength which means the wheel is not completely loaded and can be used further.  The roughness value comparison after dressing and machining for 5 min each shows a better result when compared to the before dressing operations.  Especially for the determination of the temperature at the affected zone.  The model also takes into account the effects of the thrust force and the grinding lengths. Copyright to IJARCST DOI: 10.48175/IJARSCT-631 208 www.ijarsct.co.in ISSN (Online) 2581-9429 IJAR SCT ISSN (Print) 2581-XXXX

International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 11, Issue 2, November 2020 Impact Factor: 4.819

The number of components also to be able to analyze and to compare products to define new product families. It can be observed that classical existing product families are regrouped in function of clients or features. EXPERIMENT 1 – 0.2mm - SINGLE PASS A B C D E F G H I J 2.94 3.00 2.89 2.71 2.63 2.08 2.12 2.44 2.36 2.95 EXPERIMENT 2 – 0.1mm - TWO PASSES A B C D E F G H I J 2.86 2.93 2.60 2.58 2.33 2.41 3.00 2.67 2.54 2.11 EXPERIMENT 3 – 0.05mm - FOUR PASSES A B C D E F G H I J 1.67 1.49 1.43 1.36 1.84 1.67 1.83 1.91 1.31 1.24 Table 8: Roughness Value (µm) Before Dressing

ROUGHNESS VALUE AFTER DRESSING 5.00 4.50 4.00 3.50 3.00 2.50 Exp1 2.00 Exp2 1.50 Exp3 1.00

0.50

0.00

A B C D E F G H I J

LOCATION OF Ra MEASURED

Graph 2: Comparison of Roughness Values After Dressing

IV. CONCLUSION The following conclusions can be arrived based on the results of research work.  The dressing parameter with 0.05mm depth and four passes gives better surface finish.  Temperature developed during grinding has no significant effect on properties of material.  The same conventional process will be conducted in the unconventional machining process – Abrasive Water Jet machine in the upcoming research with a small fabrication design.  The three technological developments, which consist of a direct drive servo spindle motor controlled more precisely, removable steady rests to prevent for a slender fluted hollow shaft of gun to be deflected and a highly pressure circulation system of to prevent for a cutting edge of gun drill to be broken by clogging of chips, were thoroughly effective to manufacture The accuracy of the grinding is satisfied enough for a demanded value in the items of hole diameter, concentricity, roundness and inner surface roughness.

Copyright to IJARCST DOI: 10.48175/IJARSCT-631 209 www.ijarsct.co.in ISSN (Online) 2581-9429 IJAR SCT ISSN (Print) 2581-XXXX

International Journal of Advanced Research in Science, Communication and Technology (IJARSCT)

Volume 11, Issue 2, November 2020 Impact Factor: 4.819

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BIOGRAPHY

MOHAMMED ABDUL KADAR R, M.E. Assistant Professor, Department of Mechanical Engineering, Anand Institute of Higher Technology, Chennai – 603103. Email id – [email protected]

Copyright to IJARCST DOI: 10.48175/IJARSCT-631 210 www.ijarsct.co.in