Abstract: Grinding requires high specific energy and the consequent development of high temperature at tool-workpiece contact zone impairs workpiece quality by inducing thermal damage to the surface. Finishing grinding process requires component to be cut more than one pass. This paper deals with an investigation on the effect of multipass cutting on grinding performance in term of surface roughness and surface defect. An experimental set-up has been developed for this and a detailed comparison has been done with a single pass and various numbers of cutting pass. Results showed that surface roughness increase with the increase in a number of cutting pass. Good surface finish of 0.26μm was obtained for single pass cutting and 0.73μm for twenty pass cutting. It was also observed that the thickness of the white layer increased with the increased in a number of cutting pass.
Abstract: A mathematical model of the surface roughness
has been developed by using response surface methodology
(RSM) in grinding of AISI D2 cold work tool steels. Analysis
of variance (ANOVA) was used to check the validity of the
model. Low and high value for work speed and feed rate are
decided from design of experiment. The influences of all
machining parameters on surface roughness have been
analyzed based on the developed mathematical model. The
developed prediction equation shows that both the feed rate
and work speed are the most important factor that influences
the surface roughness. The surface roughness was found to be
the lowers with the used of low feed rate and low work speed.
Accuracy of the best model was proved with the testing data.