UNIVERSITI TEKNIKAL MALAYSIA MELAKA
ANALYSIS THE CONTRIBUTION AND EFFECT OF COOLANT
TO STRAIGHTNESS IN CYLINDRICAL GRINDING
This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Process) with Honours.
by
HAIDZER ISA BIN A RAHMAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PSM
TAJUK:
“ANALYSIS THE CONTRIBUTION AND EFFECT OF COOLANT TO STRAIGHTNESS IN CYLINDRICAL GRINDING
”
SESI PENGAJIAN:
2008/2009 Semester 2
Saya HAIDZER ISA BIN A RAHMAN
mengaku membenarkan laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Laporan PSM / tesis adalah hak milik Universiti Teknikal Malaysia Melaka dan
penulis.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis.
3. Perpustakaan dibenarkan membuat salinan laporan PSM / tesis ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
4. *Sila tandakan (√)
SULIT
TERHAD
⁄ TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan atau
kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
DECLARATION
I hereby, declared this report entitled “Analysis The Contribution And Effect Of Coolant To Surface Roughness In Cylindrical Grinding” is the result of my own research except as cited in references.
Signature : ………..
Author’s Name : ………..
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Process) with Honours. The member of the supervisory committee is as follow:
(Signature of Supervisor)
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Process) with Honours. The members of the supervisory committee are as follow:
(Signature of Principle Supervisor)
………. (Official Stamp of Principle Supervisor)
(Signature of Co-Supervisor)
i
ABSTRACT
Every fourth year degree students of Universiti Teknikal Malaysia Melaka or known as
UTeM is compulsory to do Bachelor Degree Project (PSM). This is to improve
acknowledgments and skill in solve academic research problem with scientific,
systematic and born as a dedication and competence professional for full fill Program
Outcome (PO) and Program Educational Objective that fixed by FKP. The main point of
this project is to test the effectiveness of three type of coolant concentration with
appropriate to the machining operation by using Universal Cylindrical Grinder Model
OD820S in order to study the machine performance in term of straightness factor. The
objective of this project is to expose student to the important of coolant concentration use
in machining process. These projects are also including machine operating training
session in order to make student easily understand the machine principle to produce full
report writing, slide presentation and report during this project. The studies also concern
the student capability through process and maintenance. All data will be evaluated done
from the project lab result. The contribution of coolant will related to the straightness
and tested with Mahr Formtester MMQ44, after getting the result, conclusion will be able
to make for complete the report. The conclusion explains about the problems occurs and
ii
ABSTRAK
Setiap pelajar ijazah tahun 4 Universiti Teknikal Malaysia Melaka atau lebih di kenali
sebagai UTeM adalah wajib membuat Projek Sarjana Muda (PSM). Ini bertujuan untuk
meningkatkan lagi pengetahuan dan kemahiran dalam menyelesaikan masalah kajian
akedemik dengan kaedah saintifik, sistematik dan lahir sebagai seorang yang berdedikasi
dan persaingan yang profesional bagi megisi Hasil Program dan Program Objektif
Pembelajaran yang ditetapkan FKP. Tujuan utama projek ini adalah untuk menguji
kebersanan 3 jenis kepekatan cecair penyejuk dengan mengunakan mesin yang sesuai
iaitu Universal Cylindrical Grinder Model OD820S semasa mengkaji prestasi mesin
dalam kata erti lain factor kelurusan (straightness). Objektif projek ini pula adalah
mendedahkan pelajar tentang kepentingan kepekatan cecair penyejuk yang di gunakan
dalam proses pemesinan. Projek ini juga termasuk sesi latihan mengoperasikan mesin
demi memudahkan pelajar untuk memahami tentang prinsip mesin untuk menghasilkan
laporan penuh, persembahan projek dan laporan semasa projek ini. Kajian ini juga
mengambil kira tentang keupayaan melalui proses dan penjagaan. Semua data akan
dinilaikan daripada keputusan projek makmal. Sumbangan cecair penyejuk pula akan
dikaitkan dengan kelurusan dan di uji dengan mesin Mahr Formtester MMQ44, selepas
mendapat hasil ujian, penutup akan dibuat untuk melengkapkan laporan ini. Penutup
iii
DEDICATION
This work is dedicated to my parent, A Rahman Murad and Hamidah Harun. Without whose caring support it would not have been possible, and to all my friends
iv
ACKNOWLEDGEMENT
In the name of Allah,The Most Gracious, Most Graceful.
Alhamdulillah, with full effort and patience in taking all challenges, Projek Sarjana Muda (PSM) finally accomplished successfully.
A Special thanks to my supervisor, En. Mohd Amri Sulaiman for his very valuable editorial advices, comments, guidance and support.
Besides, I would like to thank my beloved parents and family for giving endless encouragement, motivation and support throughout my project. Last but not least, I would like to thank my colleagues for their cooperation.
v
2.1
Introduction to Cylindrical Grinding Machines
4
2.1.1 Cylindrical grinding process characteristics
6
2.2
Universal Cylindrical Grinding Machine
6
2.2.1 Internal Grinding Machine
7
2.3
Grinding Wheel
8
2.3.1 Selecting the Grinding Wheel
9
2.4
Raw Material Selection
10
2.4.1 Stainless Steel SUS304
10
2.4.2 Composition
12
2.5
Straightness
13
2.5.1 Straightness Factor on Cylindrical Material
13
vi
2.6
MarForm MMQ44 Formtester
15
2.7
Machines Description
16
2.9.2 Principles of Refractometers
21
2.9.3 Transparent Systems
21
2.9.4 Reflection Systems
22
3. METHODOLOGIES
23
3.1
Introduction
23
3.1.1 Summary flow chart of PSM
25
3.1.2 Diagram Flow Chart
26
3.2
Machining Introduction
27
3.3
Machining Parameters Setup
28
3.3.1 Parameter setting
28
3.3.2 Identification of the control factors and their level
28
3.3.3 Coolant Setup Parameters
28
3.3.4 Viscosity of Coolant Setup Procedure
30
3.4
Machining Samples
32
3.4.1 Machine Preparation before Machining Using
Cylindrical Grinding Machine
32
3.4.2 Machining Workpiece Using Cylindrical Grinding Machine
33
3.5
Measure and Analysis Data
35
3.5.1 Procedure to Operate
vii
4. RESULTS AND ANALYSIS
39
4.1
Introduction
39
4.2
Result of Straightness
40
4.3
Analysis Graph for Result
41
4.3.1 Graph of 3 Brix Concentrations.
41
4.3.2 Graph of 6 Brix Concentrations.
42
4.3.3 Graph of 9 Brix Concentrations
43
4.4
Comparisons of Three Types Coolant Concentrations
43
4.5
Statistical/Hypothesis Test
45
4.5.1 Procedures in Hypothesis Testing
45
4.5.2 Hypothesis Test Procedure
46
4.5.2.1 Statistical Test Comparison between 3 Brix Concentrations
with 6 Brix Concentrations
46
4.5.2.2 Statistical Test Comparison between 3 Brix Concentrations
with 9 Brix Concentrations
48
4.5.2.3 Statistical Test Comparison between 6 Brix Concentrations
with 9 Brix Concentrations
50
4.5.3 Summary
52
5. DISCUSSION
53
5.1
Introduction
53
5.2
Influences in coolant concentrations
53
5.3
Influences in Grinding Operation
54
5.3.1 The Straightness Influence factor by Work Head speed
54
5.3.2 The Straightness Influence factor by Traverse Length
55
5.3.3 The Straightness Influence factor by Depth of cut (wheel infeed)
55
5.3.4 Dressing
55
5.3.5 Un-uniformity Dressing
56
5.3.6 Spark
56
5.4
Influence in Method of Measurement
57
viii
6. CONCLUSION
58
6.1
Conclusions
58
REFERENCE
60
APPENDIX A
APPENDIX B
APPENDIX C
APPENDIX D
APPENDIX E
APPENDIX F
APPENDIX G
ix
LIST OF TABLE
2.1 Composition Ranges for Grade Stainless Steel SUS304 11
3.1 The Level of Process Parameter for Cylindrical Grinding Machine 28
Table a: Gantt chart of Projek Sarjana Muda 1 24
Table b: Gantt chart of Projek Sarjana Muda 2 24 3.2 The data for experiment using Coolant A (3 brix concentration) 29 3.3 The data for experiment using Coolant B (6 brix concentration) 29 3.4 The data for experiment using Coolant C (9 brix concentration) 30
4.1 experimental Straightness result of coolant 3 brix for 40 stainless steel SUS304
4.2 experimental Straightness result of coolant 6 brix for 40 stainless steel SUS304
4.3 experimental Straightness result of coolant 9 brix for 41 stainless steel SUS304
4.4 Average value for each coolant type 43
4.5 Straightness Average for Coolant Type 3 Brix and Type 6 Brix 46
4.6 F-Test Two-Sample for Variances 46
4.7 T-Test: Two-Sample Assuming Unequal Variances 47 4.8 Straightness Average for Coolant Type 3 Brix and Type 9 Brix 48
4.9 F-Test Two-Sample for Variances 48
4.10 T-Test: Two-Sample Assuming Unequal Variances 49 4.11 Straightness Average for Coolant Type 6 Brix and Type 9 Brix 50
4.12 F-Test Two-Sample for Variances 50
x
LIST OF FIGURE
2.1 Universal Cylindrical Grinding Machine Model OD-820 H 6
2.2 Internal Grinding Machine 7
2.3 Stainless Steel SUS304 Raw Material 10
2.4 The Illustration of Straightness 13
2.5 Cylindricality Tolerance Specification 14
2.6: Straightness of a Median Line Tolerance Specification 15 2.7 MarForm MMQ 44 Formtester to Measure Straightness 17
2.8 refractometer 20
2.9 transparent system 21
3.1 summary flow chart of PSM 25
3.2 Diagram Flow Chart 26
3.3 Flow chart of Machining Process Sequences 27
3.5 3 brix concentration of coolant (view through refractometer lens) 31 3.6 6 brix concentration of coolant (view through refractometer lens) 31 3.7 9 brix concentration of coolant (view through refractometer lens) 31
3.8 Workpiece Dimension 32
3.9 Band Saw Machine 32
3.10 Lathe Machine 33
3.11 Workpiece Dimension 33
3.12 Universal Cylindrical Grinding Machine model OD-820 H 35 3.13 MarForm MMQ 44 Formtester to Measure Straightness 36
3.14 Clean specimens sample 37
3.15 Setting the Centering and Tilting Parameters 37
3.16 Running the Centering and Tilting Operations 38
xi
4.1 graph plot for average straightness result of 3 brix concentration 41 4.2 graph plot for average straightness result of 6 brix concentration 42 4.3 graph plot for average straightness result of 9 brix concentration 43
4.4: Graph of three type coolant concentration. 44
xii
LIST OF ABBREVIATIONS
FKP
-
Fakulti Kejuruteraan Pembuatan
Mn
-
Manganese
Ni
-
Nickel
PSM
-
Projek Sarjana Muda
R
-
Radius
RPM
-
Revolution per Minute
S
-
Sulphur
Si
-
Silicon
Syn
-
Synthetic
UTeM
-
Universiti Teknikal Malaysia Melaka
In
-
Inch
In/min
-
Inch per Minute
Mm
-
Millimeter
µm
-
Micron Meter
µ
-
Micro
1 Grinding is one of most important technologies used by manufacturing today. Used to machine and finishing the materials, grinding is in many cases the only method available to engineers, particularly when ceramic or new composite materials are involved. In other cases, grinding competes with other technologies and offers the most economical way to produce precision component. As compared with other machining processes, grinding is a costly operation that should be utilized under optimal conditions.
2
In Faculty of Manufacturing Laboratory in Universiti Teknikal Malaysia Melaka there were new types of machine called Cylindrical grinding machine. Hence, this report is mainly purpose to cover the study of performance coolant by using cylindrical grinding. This study also to determine the machine capability in term of producing high accuracy and precision, the highly product finishing that can influence by straightness to the product.
1.2
Problem Statement
Coolant is an important factor during grinding surface process. However, the people are not concern about the coolant condition during the process. But, the concentration of coolant is the one of the factor gave effect on surface machining. For this research, the contribution and effect will be test upon the material stainless steel SUS304. This study will develop the appropriate parameter for cylindrical grinding machining that can be used for practice and as a guide line for industry and future research of student.
1.3
Objectives
(a) To study the contribution and effect of coolant to product surface while using Cylindrical Grinding machine in FKP Laboratory
(b) To analyze the straightness factor of the finish stainless steel SUS304 product using Mahr Formtester MMQ44 at the university Metrology Lab.
3
1.4
Scope Project
4
CHAPTER 2
LITERATURE REVIEW
2.1
Introduction to Cylindrical Grinding Machines
A grinding machine is a machine tool used for producing very fine finishes or making very light cuts, using an abrasive wheel as the cutting device. This wheel can be made up of various sizes and types of stones, diamonds or of inorganic materials (Anon. 2008, July 24). There are many types of grinding machine depend on the surface of material that have to finishing. A machine grinding cylindrical surfaces is called a cylindrical grinder. Machines designed for special functions, such as tool grinding or cutting off, are designated according to their operation (Boothroyd, G. and Knight, W. A. 2006).
Cylindrical grinding machines are used extensively in engineering workshops and industries for finish pre-machined and heat-treated components. Grinders can rough out and finish the work to fine tolerances. The smooth surface and great accuracy can be obtained more economically on grinders than other machines.
In Manufacturing Laboratory, the machine that is use for this study is conventional Universal Cylindrical Grinder Model OD 820H, with variable speed table and manual wheel head in feed manufactured by SHARP Precision Machine Tools. The machine has the capability to machine both of internal and external cylindrical grinding.
5
axis of work piece rotation, and horizontal, hydraulic feed can be applied to the wheel head in a direction normal to the axis of work piece rotation; this motion known as in feed.
A cylindrical surface being generated using the traverse motion; an operation that can be linked to cylindrical to cylindrical turning where the single point cutting tool is replace by a grinding wheel. (Boothroyd, G. and Knight, W. A. 2006)
The cylindrical grinder traverses the work, to and fro, in repeated passes along the length of the diameter, and the time to traverse is found using (Ostwarld, P.F. and Munoz, J. 1997):
Where;
Ls = Length of ground dimension on workpiece, in.
Ts = Total rough or finish stock depth removed from diameter, in.
D = Original workpiece diameter, in.
W = Wheel width, in.
P = Traverse for each work revolution in fraction of wheel width
fi = Infeed of wheel per pass, in./pass
v = Workpiece peripheral velocity, in. /min
Time /pass = Ls x Ts x D
6
2.1.1 Cylindrical grinding process characteristics
a) Produces straight, tapered, and formed cylindrical workpieces b) Produces highly accurate surfaces and smooth finishes c) Is primarily a final machining process
2.2
Universal Cylindrical Grinding Machine
The universal grinding machine is very similar in construction to a plain grinding machine, except for the work head and the wheel head, both of which swivel. The work head swivels on a graduated base to 10° either side of zero. The wheel head platen not only swivels through 180° either side of zero, but is also mounted on a slide that swivels independently through 80° to 90° either side of zero. Thus, the slide can be set to the grinding angle required, and the platen swivelled through 90° presenting the wheel/face parallel to the face to be ground. A semi-universal machine in common use is very similar, except that the wheel platen and slide do not swivel independently of each other.
7 2.2.1 Internal Grinding Machine
(a) The essential elements of an internal grinding machine are: i. A work supporting chuck or faceplate. ii. A rotating grinding wheel.
From Figure 2.2 it shows that the grinding wheel is used to grind the internal surface of a hole in a workpiece supported by the chuck or the face plate. The universal grinder can be adapted for internal grinding by fitting an attachment. On modern machines, this attachment is a standard fitting driven by its own motor and can be quickly moved into position on the front of the wheelhead. Internal grinding is used to grind cylindrical, tapered or formed holes in workpieces.
