Investigation of the influences of grinding parameters on grinding forces and surface quality in surface grinding

Ill INVESTIGATION OF THE INFLUENCES OF GRINDING PARAMETERS ON GRINDING FORCES AND SURFACE QUALITY IN SURFACE GRINDING (PhD Thesis) Halil DEMİR GAZI UNIVERSITY INSTITUTE OF SCIENCE AND TECHNOLOGY November 2003 ABSTRACT In this study, a strain gauge based dynamometer for surface grinding machine has been designed and constructed in order to investigate the effects of grinding parameters on the cutting forces during surface grinding. Necessary hardware and software were used to convert analogue grinding force data to digital and to save them on a computer. Grinding tests were conducted on AISI 1050 and AISI 4140 workpieces using different abrasive sizes, grinding wheel structures, grinding wheel hardness and depth of cuts. During the tests, grinding forces were measured by keeping the grinding wheel speed, wheel dressing ratio and coolant flow constant. In addition, surface roughness values of the ground surfaces were also measured. Theoretical cutting force calculations were performed based on the depth of cut and workpiece material in order to compare them to the ones experimentally obtained. The results showed that there were considerable differences between the theoretically calculated cutting forces and experimentally obtained ones. Increasing abrasive grain size and depth of cut increased the cutting forces and workpiece surface roughness. Although, significant differences in cutting forces were not observed at the depths of cut of 0,01 - 0,03 mm, further increases in the depth of cut increased the grinding forces by approximately 50 %. When the number of passesIV decreased have been increased, it has been observed surface roughness values decreased significantly. In addition, AISI 4140 led to the higher cutting forces by 20-30 % than AISI 1050 in all the tests. Science code : 708 Keywords : Surface grinding, Grinding forces, Dynamometer, Surface roughness, Wheel grain size Page number : 156 Advisers : Assist. Prof. Abdulkadir GÜLLÜ Prof. Ulvi ŞEKER