Optimization of Cylindrical Grinding of Alloy Steel using desirability function approach

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 12 | Dec 2022 www.irjet.net p-ISSN: 2395-0072
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Optimization of Cylindrical Grinding of Alloy Steel using desirability
function approach
Sudhanshu Gulve, Purushottam Kumar Sahu2,
1BM College of Technology, RGPV, Indore MP
2Reseaech Scholar, BM College of Technology, RGPV, Indore MP
---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - The analysis of variance (ANOVA) results for a
single optimization corroborate the previous finding by
showing that the depth of cut has the greatest influence
(92.06%), followed by the cutting speed (4.65%) andfeedrate
(0.94%) with the least influence on the MRR values. The
calculation of the grey relational grade in equation (7)results
in a value of 0.4413, indicating that the ideal collection of
input control parameters is A2B3C1. Table 5.9 displays the
results of the confirmation experiment for the response
parameters. It should be noted that the experimentalvaluesof
Cutting Speed (VC) in rpm, Depth of Cut mm, and Feed Rate
mm/rev are all greatly improved by GRA.
Key Words: cylindrical grinding, material removal rate,
and desirability factor. En9 alloy steel, single optimization
1. INTRODUCTION
1.1 How Does Grinding Work and What Is It?
In modern production, machining that uses high-speed
abrasive wheels, pads, and belts are referred to as
"grinding." Grinding wheels come in a wide range of
diameters, contours, and abrasive kinds. The following
chapters will go through the most common wheel and
abrasive kinds. Grinding is one abrasive machining
technique. Abrasive machining methods include polishing,
lapping, honing, and other sophisticated finishing
treatments. There are several aspectsofgrindingtechnology
that overlap with this broad range of tasks. The only factor
that distinguishes grinding from other processes is their
kinematics, some of which, like lapping, need quite little
frictional force. Rarely, the abrasive process can be aided by
chemical or electrochemical principles, extending the
grinding process.
The concepts and methods given in this book can be
applied to other aspects of super finishing, even though the
mechanical friction process is the primary focus of the
majority of thetechniquesandprinciplesdiscussed.Grinding
is a process used to remove material and increase surface
area in order to condition and polish metal and other
materials. Ten times more accuracy may be achieved
through surface finishing and grinding than through milling
or even turning. A substantial abrasive product—typically a
rotating wheel—makes contact with the work surface when
grinding. [3]
This chapter explores the role that grinding plays in
modern production, including its origins, how it works, and
how it relates to strategy. As top concerns, cost, quality, and
manufacturing speed are cited. ability to learn from
machines Low surface roughness,goodsurfaceintegrity, and
high precision with very hard materials like steel and
ceramics are distinctive characteristics. Current trends
include accelerating production rates, using tougher and
more advanced abrasives, and developing machines and
control systems with ultra-precise capabilities. The
fundamental mechanisms and components of grinding
systems are described. The mainobjectiveandcontentofthe
book are described in order to demonstrate its structure.
Other relevant texts are referenced.
Figure 1.1.Four fundamental grinding techniques are
shown in there are four types of grinding: face surface
grinding, face cylindrical grinding, and peripheralcylindrical
grinding.
1.4 Element Specifications
The following information is included in a system
specification.
Work piece material: Form, stiffness, hardness, and
chemical and thermal characteristics.
Type, control system, precision, rigidity, temperature
stability, and vibrations of grinding machines

Figure 1.2 shows external center less grinding, external
angle grinding, and internal cylindrical grinding. [17]
The movements and geometry that control how the
grinding wheel makes contactwiththeworkpieceareknown
as kinematics. The speeds and feeds of the wheel and the
work pieces.
• The features of grinding wheels in terms of abrasive,
particle size, bond, structure, hardness, speed, stiffness, and
chemical composition.
• Dressing circumstances: the kind of tool, feeds and
speeds, cooling, lubrication, and maintenance.
• The flow rate, velocity, pressure, physical,chemical,and
thermal characteristics of the grinding fluid.
Temperature,humidity,andtheimpactoftheatmosphere
on the environment.
• Risks to the public and machine operators' health and
safety.
• Waste management.
• Costs.
The Variety of Grinding Methods and References
The full spectrum of grinding operations, which includes
single-sided or double-sided face grinding of numerous
components placed on a planar surface, is very broad in
actuality. The range also contains operations for creating
profiles and copying profiles. Grinding spiral flutes, screw
threads, spur gears, and helical gears employing techniques
akin to gear cutting, shaping, planning, and robbing with
cutting tools are all examples of profiling operations. Other
techniques can be used to grindcampmates,rotarycams,and
ball joints. [17]
2. Objective of work:
The goal of this work is to identifythemachiningparameters
in an external cylindrical grinding operation that should be
optimized on MRR using the Taguchi technique, response
surface analysis, and theGREYconnectionanalysisapproach.
The three characteristics knownas "cuttingspeed,""depthof
cut," and "feed rate" are thought of as the ideal cutting
parameters. The precise objectives are listed below. a) To
practice design of experiments (DOE) using the cylindrical
grinding method (CGP). b) To determine the ideal cutting
conditions for raising MRR.
3. Methodology:
DESIGN OF EXPERIMENT: Experiment design is a method
created to comprehend the behavior of a mechanicalsystem.
Data are accumulatingfromthevariablesetsets,andtheycan
be used to qualitatively explain the current situation.
Therefore, it is commonly recognized that the goal of any
research is to construct an experiment with a minimal
number of variables and use this experiment to gather as
many data as feasible. Every experiment focuses on the
majority of the variables that can have a direct impact on the
outcomes. Quantities that have a significant impact on the
results of studies can be used to detect these types of factors.
One of the most crucial ideas in science is theories, which are
used to guide further experiments.
Alloy steel EN6 is chosen as the work piecematerialinthe
study presented in [1]
Table 3.1 L27 orthogonal array and results.

Table 3.2 Control Parameters and their levels [1]
The number of components and the levels chosenforthesets
of variables determine how many duplicates are present in
the experiment; as the number of experiments increases, so
will the number of replicates. Different methods, such as the
Taguchi Method, Response Surface Method, Mixture Design,
and Full Factorial Method, are employed in the design of
experiments. Each experiment has its own significance, and
the ideal approach depends on the circumstances or the
different types and weights of the many components.
Fig 3.1 Main Effects Plot for SN ratios of MRR
Table 3.2 Response Table for Signal to Noise Ratios
Larger is better
Level Cutting Speed DOC Feed Rate
1 4.568 2.920 4.790
2 5.846 4.711 5.433
3 5.233 8.017 5.425
Delta 1.278 5.097 0.643
Rank 2 1 3
Because MRR is a larger-is-better kind of quality
characteristic, the major effect plot (Figure 3.1) shows that
the second level of cutting speed (A2), first level of depth of
cut (B1), and third level of feed (C3) offer the highest MRR
value. Relatively slightly, the MRR increases along with the
feed rate and cutting speed. The MRR, on the other hand,
increases considerably if the depthofincisionisincreased by
0.02 mm.
Model Summary: Finally the regression equation is
shown give the exact model equation or it will show the
relationship between the input and the output variables.
Fig 3.1; Contour plot of MRR
The Effect of the machining parameters (cutting speed,
feed, and depth of cut) on the response variables MRR has
been predicted. It can be seen from Fig. 3.1, TheMRR tendsto
increase significantly with increase in feed rate and depth of
cut for any value of grit size.

The residual plot for the Material Remover Rate is
displayed above. The first graph in this graph is the normal
probability graph, in which all the points are located along
the normal probability line. This indicates that the data are
well fitted for the observation and that there must be a
significant correlation between the input and the output
variables The second graph is a histogram plot in which the
greatest value is plotted at 0, indicating that the majority of
the data were either zero or that there is no difference
between the residual probability graph and the normal
probabilitygraph.Theresidual'sdeflectionisdisplayedasthe
number of observations in the final graph. The final graph
displays the deflection in the residual with respect to the
number of observations. Themaximumdatainthehistogram
plot are on 0, which also means there isn't a lot of space
between the data and the normal probability line.
Numerical optimization
The purpose of this research is to find the best parametric
settings to achieve maximum Material Removal Rate of
grinding process at the same time, which is ideal for good
grinding efficiency. The desirability analysis is used to
determine the best parametric setting to obtain theabsolute
Material Removal Rate of the grinding process. The grinding
process is optimized using the Minitab18 program. The
common steps and procedures that are followed in the
Minitab software are described in detail here. The results of
multi-objective optimization for Material Removal Rate are
shown in fig. 4.1. Optimal Material Removal Rate
2.816(Gm./Min) has been obtained at(a) Cutting Speed(VC)
in rpm A2 1900 rpm (b) Depth of cut (mm), B30.06 mm. (c)
Feed Rate 0.04 (mm/rev)C1 The mixed desirability factor D
has a value of 0.93650.
Fig. 4.1 Optimization results of Material Removal Rate by
RSM
4.2 Confirmation test
The obtained optimization techniqueswereconfirmedusing
validation studies. Table 4.1 shows the results of
confirmatory tests performed under ideal conditions. It is
seen from the table that the error in terms of percentage
between the estimated and experimental results is very
small and is less than 1%. This indicates for single
optimization, for cylindrical grinding, there is significant
improvement with the experimental alloy steel
EN9.Parameters. Three fresh experimentsareconductedfor
confirmation of models Eqs. (3) And (4), with achieved
optimal values of Material Removal Rate. The average of
measured values for Optimal Material Removal Rate 2.816
(Gm./Min) has been obtained at(a) CuttingSpeed(VC)inrpm
A2 1900 rpm (b) Depth of cut (mm), B3 0.06 mm. (c) Feed
Rate 0.04 (mm/rev) C1. The accuracy of the models is
analyzed on the basis percentage error. . Since the error is
less than10%, it is evidently proved that there is a good
agreement between experimental and predicted values
[38].Finally,within experimental constraints,anattemptwas
made to estimate the optimal cylindrical machiningposition
to provide the best desired results.
Table 4.1 Multi-objective optimization results

4. The studies led to the following conclusions:
1. The Taguchi orthogonal array has been utilized
successfully to determine the ideal level of process
parameter setting.
2. Because MRR is a larger-is-better type of quality
characteristic, the main effectplot(Figure3.1)demonstrates
that the third level of feed (C3), the first level of depth of cut
(B1), and the second level of cutting speed (A2) provide the
highest values of MRR between the input and output
variables. Consequently, there is a significant correlation
between the input and output variables.
3. For a single optimization, the analysis of variance
(ANOVA) results based on the estimated MRR values are
shown in Table 3.3. These results demonstrate that the
depth of cut has the highest contribution (92.06%),followed
by the minimum influence from cutting speed (4.65%) and
feed rate (0.94%), in determining the MRR values, thereby
validating the conclusion reached above.
4. R-sq: In order to anticipate a good agreement betweenthe
input and output values, the R-sq value must be over 40%,
according to the research technique. The R-sq value is
97.64% in the table below, which illustrates the good
agreement between the input and output variables. As a
result, there is a significant correlation between the input
and output variables.
References:
1. Pravin Jadhav, Pranali Patil, Sharadchandra Patil.:
Optimization of Cylindrical Grinding for Material Removal
Rate of Alloy Steel EN9 by Using Taguchi Method. Advances
in Industrial and Production Engineering,SelectProceedings
of FLAME 2020 (pp.851-859)
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