Single Grit Grinding Case Study Answers

CHAPTER 3
EXPERIMENTAL SET UP
3.1 MATERIALS AND METHODOLOGY
Material used are:
1. Silicon Carbide
2. Aluminium Wheel (11.5 diameter)
3. Diamond single grit
4. Force sensor (Kistler 9256C2)
5. CNC lathe (ACE Jobber LM)
6. Profile Projector
7. Drilling Machine
8. Vertical Milling Machine
The following table names the different independent variables used and their levels.

Table 3.1: Levels of independent variables
Independent Variables Levels 1 2 3 4
Speed of Wheel (rpm) 250 300 350 400
Grit Orientation (⁰) 30 45 60 90
Depth of Cut (cm) .6 .8 1 1.2

By varying the above stated independent variables through their different levels, the grinding force and material removal rate models were obtained.
Since there are four levels and three

The silicon carbide block (150x50x25 was cut into smaller and required dimensions of 10x50x25
2. The Single Grit Grinding (SGG) experiment on a CNC lathe (ACE Jobber LM) was conducted with the help of a special attachment which was specifically designed and fabricated for this specific experiment itself.
3. This special attachment consisted of a base firmly screwed onto tool turret of the lathe and a piezoelectric force sensor (Kistler 9256C2) clamped firmly on to the base. Finally the workpiece is mounted on top of the force sensor with the help of additional extensions, supports and nails. The setup is shown in Fig 3.1 to Fig 3.3 Fig 3.1 Experimental set up of Dynamometer Fig 3.2 Experimental set up of Workpiece Fig 3.3: Experimental Set Up
4. The scratch was obtained with the help of a fabricated aluminium wheel (11.5 cm in diameter) with a single grit diamond attached on to the wheel as shown in Fig 3.3.
5. Each of the slots where the single grit is placed gives us a different grit angle ranging from 30⁰ to 90⁰.
6. The aluminium wheel was fabricated using a manual lathe machine. The operations conducted to fabricate the wheel were:
1.

The profile projector used was able to magnify and measure the scratch depth, width and length.

CHAPTER 4 OBSERVATIONS
After 64 scratches were obtained and observed with the help of the dynamometer and profile projector, the values obtained were tabulated as follows:
Table 4.1: Observation Table
Sl. No. Speed(m/min) Depth(m) Grit angle(°) Radial force (N) Tangential force (N) Scratch width (cm)/100 Scratch depth (cm) Scratch length (cm)
1 86.35 0.0006 30 84.1294 22.8956 0.696 0.131 2.096
2 86.35 0.0008 30 84.8365 23.2654 0.708 0.135 2.092
3 86.35 0.001 30 85.4796 23.6487 0.716 0.148 2.099
4 86.35 0.0012 30 86.0364 24.3647 0.727 0.152 2.105
5 86.35 0.0006 45 84.3859 22.6987 0.729 0.137 2.042
6 86.35 0.0008 45 85.0149 23.0345 0.739 0.142 2.087
7 86.35 0.001 45 85.8126 23.6789 0.745 0.145 2.088
8 86.35 0.0012 45 86.3248 24.5095 0.765 0.149 2.091
9 86.35 0.0006 60 84.6258 22.4506 0.755 0.139 2.111
10 86.35 0.0008 60 85.8974 22.9678 0.761 0.141 2.132
11 86.35 0.001 60 86.0129 23.4136 0.776 0.146 2.145
12 86.35 0.0012 60 86.5364 24.0165 0.789 0.149 2.123
13 86.35 0.0006 90 85.0268 22.492 0.801 0.143 2.154
14 86.35 0.0008 90 86.1294 23.2435 0.807 0.145