View of Fabrication of Carbon Steel Plate Re- Grinding Machine for Automatic Flour Machine

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13124 http://annalsofrscb.ro

Fabrication of Carbon Steel Plate Re- Grinding Machine for Automatic Flour Machine

Chitharthan S¹, Bala murugan M², Dhanush R³,Gunaseelan S⁴, Suriya D⁵

1Assistant Professor, Department of Mechanical Engineering, Karpagam College of Engineering, Coimbatore, Tamil Nadu, India. Email ID: [email protected]

2,3,4,5

UG Scholar, Department of Mechanical Engineering, Karpagam College of Engineering, Coimbatore, Tamil Nadu, India

ABSTRACT:

Grinding is an abrasive machine operation that is used to increase the surface quality of a work piece as well as achieve dimensional precision. Surface roughness and material removal rate are important performance responses for production quality and quantity in grinding. The most difficult and accurate machining method is grinding. However, due to the complexity of the procedure, developing a reliable measurement method to detect grinding wheel loading phenomena during the grinding process is extremely difficult. The main aim of this study is to use three parameters to investigate the effect of abrasive tools on the surface of EN24 steel.

This research was carried out with the help of a surface grinding machine.

1.Introduction

The grinding process is typicallya finishing and machining process basically performed in the last finishing operation on a work piece. As with milling or spinning, a grinding wheel is used as a cutting tool, and material is stripped from the work piece. Grits on the grinding wheel surface, associated with increased speeds, established a large number of small cutting edges instead of a single massive cutting edge. Both grits will remove a small amount of material from the work piece. Despite the reality that small grit chips are generated, the part can make a considerable number of grits with surface quality finishing and high precision.Rough grinding, also known as precision grinding, is a method that is used to grind castings and weldments with lightweight grinders or pedestal grinders. Precision grinding, also known as fine grinding, is used to machine components or techniques that are too difficult to process, or operations that need a high surface finish and precise tolerance levels on the order of 0.02 mm. After grinding, quality issues such as geometrical errors or a poor surface finish cannot be addressed. Surface roughness and the rate where the material is removed are critical processes. Surface roughness relates to the cutting tool's finely dispersed contoured surface irregularities. As a response, materials such as pistons, piston pins, crankshafts, as well as other fine surface are important in many engineering applications. The material removal rate is expressed as the proportion of material removed per unit of time. When the rate of material removal is higher, the process can take less time to complete.

2. Literature Review

H. Adibi [01] examined at a conceptual results of wheel loading as a function of cutting parameters, wheel structure, and material properties.N. Alagumurthi [02] Heat produced during grinding is an important performance factor to consider during the finishing process.

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Experimentation and statistical analysis are two examples of research activities that help manufacturers improve their component performance. The thermodynamics and heat generation of OHNS steel during the cylindrical grinding process are investigated in this analysis.R. Deiva Nathan [03] The occurrence of burn marks on the work surface has been examined as a criterion of wheel life; as an outcome, the duration of the occurrence of grinding burn during cylindrical plunge grinding of steel has been analyzed under numerous grinding conditions.K. Salonitis [04] This article addresses residual stress profile simulations and forecasting as a function of process parameters. The model's observations are established for two categories of AISI 1045 steel hardening: dry grind and coolant assisted grind.

M. Dauda [06] The production of an identical shaft diameter model was investigated and discussed. The model is based on the weights, diameters, rigidity moduli, and densities of the members of a solid series composite shaft, and it ensures that the corresponding shaft, whose length is then calculated, has the same mass as the composite shaft.

B. Kolkwitz [07]They focused at how to put additional emphasis on parameter set determination for optimum grind-hardening in outer-diameter grinding. On the one hand, metallographic investigations were used to perform grinding experiments, and on the other hand, a finite-element-based model was used to predict the surface integrity of grind- hardened components.

J.M. Llobet [09] They learned to create a better domestic grinding machine which can be used in the kitchen to grind vegetables, spices, and grains in any shape. The incorporation of a magnetic material at the exit compartment identified as the extractor has solved the challenges of sorting grinded ferrous metallic particles from the grinded products. A.C. Miu [10] have scrutinized the prospects of Al-amyloid cascade studies and other existing lines of evidence which might shed light on the interaction between Al and AD.

3.Methodology

Design Plan

Run Experiment According to Design Plan Experiment Result Obtained

Perform Analysis Base on RSM Confirmation run

End 3.1 Pneumatic tool used with technical specification 3.1.1 Pneumatic time controller

Pneumatic timers are used to regulate time of air input signals accurately and transform air input signals into an ON or OFF delay timing mechanism that signals other pneumatic valves

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or devices. A clock timing hand or figure wheel may be used to mechanically display the timing of air input signals for fast and simple time cycle indication. Other timing devices use volume fill or spring diaphragm technology and do not display a process value due to their design.

Fig.1. Pneumatic time controller

Pneumatic timers are commonly used in solely pneumatic systems where no electrical power is available or where electrical power is likely to be dangerous; pneumatic timers are considered inherently safe in these areas. Our pneumatic timers are entirely interchangeable with those from other suppliers, as well as being reasonably priced and often available from stock.

3.1.2 Pneumatic Double Acting Cylinder

Many industrial applications stipulate linear motion as part of their operation. A pneumatic actuator, also known as an air cylinder which is the easiest and costliest effective ways to operate. Actuator is a device that converts a source of static power into a useful motion and also used to apply pressure. It is a mechanical device that transform energy into different forms of motion including blocking, clamping, and ejecting.

Fig.2. Pneumatic Double Acting Cylinder 3.2 Mechanical Tool Used in Technical Specification

Fig.3. Mechanical Tool

Air compresor/

DC supply

2cylinderValve

Time controler

Micro 8051 Blade

Gear Motor Rotating table

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4.Implementation

4.1.ResponseSurfaceMethodology(RSM)

Response Surface Methodology is a set of statistical and mathematical techniques for developing, improving, and optimizing processes in the design, manufacture, and formulation of new products, as well as the use of existing product designs.This field includes analytical statistic modelling to create a reliable approximating relationship between the yield and process variables, as well as an experimental technique for exploring the length of the process or independent variables. The fields of RSM also include optimization methods for determining the levels or values of process variables that produce desirable response values.

4.2Theoretical analysis

The product is pushed into the grinding section as the lever rotates, and the product is ground into power as the two discs rub against each other.

The unique conditions that the various parts of a domestic grinding machine are subjected to necessitate the selection of appropriate materials for fabrication based on functionality, durability, vibration resistance, and cost.

4.3 Spindle's Design Requirements The spindle parts deflection

For performance outcomes, we would like to keep the number of parts in the spindle as low as possible, so the distance between the two bearings is evaluated using the permissible shaft deflection between bearings, which is specified by the following relationship.

Y= (1.10^-4 / 5.10^-4). L [mm] (1)

where

Y = shaft deflection between the two bearings [mm]

L = distance between two bearings [mm]

A appropriate dimension of the shaft spindle must be used to generate the minimum possible load on the bearing using its own weight. The relationship for the used bearings expresses it.

Pm = 0.01 Cn [N] (2)

Where

The minimum equivalent load is Pm. [N]

The bearing's static load capacity is denoted by Co. [N]

Sufficient passive forces for grinding

Between the grinding wheel and the work piece, a total cutting force works in a general direction during grinding. The total cutting force is divided into three mutually perpendicular elements, as shown in Fig. 4. The most significant factor at work here is the force of inaction FP, which is perpendicular to the grind surface. Cutting force FC acts in the cutting speed direction, while feeding force FF acts in the feed direction. Before the spindle can be designed, the optimal size of the FP must be calculated.

Fp = (1.2/3). Fc [N] (3)

Fp = (2/10). Fc [N] (4)

The optimal theoretical passive force is relatively difficult to determine 5.Design Analysis

Mass of the hopper = Density of mild steel X volume of hopper.

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M = ρ x V

Volume of hopper = External volume of the hopper – Internal volume of the hopper Where:

Volume of the hopper = ] For equivalent length of a composite shaft Density of steel (ρ) = 7850kg/m3

L = (equivalent length) Where:

G - Rigidity modulus of the corresponding shaft (N/m²) G1 - Rigidity modulus of the shaft [1] (N/m²)

G2 - Rigidity modulus of the shaft [2] (N/m²) G3 - Rigidity modulus of the shaft [3] (N/m²)

The lengths of the corresponding shafts, shaft (1), shaft (2), and shaft (3), respectively, are L, L1, L2, and L3.

T = Driving Torque = Resisting Torque (N/m)

Where d, d1, d2 and d3 are the diameters of the equivalent shaft, (1), (2) and (3) respectively.

Determination of Composite Shaft Diameter

Fig.4.cutting force component d= [∑()

Mass of each shaft: mi = m1 + m2 + m3 Diameter of each shaft: di = d1 + d2 + d3 Capacity of the Feeding Chamber

V = 𝜋r²h Where

V – Volume (cm³) R - radius (m) h – height (h) V=𝜋r²h

Angel of twist for the composite sheet Ө= Ө1+ Ө2+ Ө3=

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Ө=

Torque T=^Ө (Nm) Power P = (w)

Volume of the Composite Shaft V=

Calculating the Magnetic force (force between Magnets) F=

Where F – force, N

A - cross sectional area of the pole in m² B – magnetic induction exerted by the magnet 5.1Experimental Details

This experimental investigation was carried out in the study work material, EN24steel on a CNC grinding machine. The dimension of the work piece is 75mm*38mm*20mm.

Micro 8051 is used to make the grinding wheel. 350mm OD*40mm width*127mm ID grinding wheel the experimental setup used in this analysis is depicted in this diagram.The responses addressed in this report are surface roughness and material removal rate..surfeit SJ- 301 surface roughness tester was used to assess the surface roughness.

MRR=

Where,

W_o – weight of workpiece material before machining (g) W_a– weight of workpiece material after machining (g) T – Machining time (min)

If experimental data are collected from the research, this section deals with the results and interpretation. The variables that were investigated.Random sampling of the run order and analysis sequences in this article were the outcomes of the run order by design expert 6.0 software.

5.1.1Experimental Results with Micro 8051

Table 2 shows the experimental results of EN24 surface finishing with a Micro 8051 wheel.

According to this phase outlined for two levels of factorial design, the results are entered into the design expert programmed for review. The disclosed design status was evaluated without performing any transformations on the responses, and all of the information was used for further study.

5.1.2Effect of Process Parameter on Surface Roughness (Ra)

Expert in design 6.0 The values were calculated using software. The impact of the variable process and the second order quadratic model of interaction for Ra are summarized using ANOVA. This model was created with a 95%trust level. The model's F value of 19.72 suggested that it is important, with noise having little effect. When F and P values are compared, it is clear that factor A (wheel speed) has the greatest impact on Ra. With a

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contribution of 0.7 percent, this factor has a P value of 99 percent, indicating that it has a high effect. The model words A and A2 are meaningful if the value “Prob>F” is less than 0.05.If the value is greater than 0.1, the model terms are not significant.The F value of 0.62 indicates that it is not statistically important as opposed to pure error

5.2Experimental Details

On a CNC grinding machine, the experimental investigation presented here was carried out.

EN24 steel was chosen as the study's work material. The dimension of the work piece is 75mm*38mm*20mm. The Micro 8051 grinding wheel has the following dimensions:

350mmOD*40mm width*127mmID. The experimental setup used in this analysis is depicted in this diagram. The responses examined in this report are surface roughness and material removal rate. Surftet SJ-301 surface roughness tester was used to assess the surface roughness. The rate of material removal is used to assess machining efficiency. The material removal rate is determined under the equation and expression of the sum of material removed over a period of the process.

MRR=

This section deals with the study's findings and interpretation of the experimental results. The variables that were investigated. According to the run order in this article, the design expert 6.0 software was used to randomly select the run orders and research sequences.

Table 1. Process parameters

6. Result and Discussion 6.1. Surface Roughness

A comparison of the experimentally measured roughness Ra, measured AE signals, and calculated wheel loading has been used to evaluate the material removal volume. In these statistics, the determined surface roughness Ra is sampled ten times and the average value is used. Throughout the first step of grinding, the recorded surface roughness Ra (between 0.38 and 0.58 m) remains unchanged, as shown. The determined surface roughness Ra multiplies exponentially with the material removal volume at the final phase of grinding (between 0.58 and 0.82 m). It may be because the grinding wheel's potential to grind is weakening as a result of detached chips gathering on the surface and contamination affecting grinding accuracy. As a result, the work piece's first-stage grinding efficiency is higher than the final- stage grinding efficiency.The computed surface roughness Ra exhibits the abnormal result as the measured wheel loading number and AE signals.

6.1.1Experimental Result with Micro 8051

As an experiment, the Micro 8051 Wheel was used to finish the surface of EN24. The outcome is entered into the Design Expert software for further analysis using the two-stage half factorial design measures described above. The disclosed design status was assessed

Factor Process parameters Levels of factor Low (-1) High (+1)

A Wheel speed (RPM) 450 1200

B Table speed (m/min) 4 16

C Depth of cut (µₘ) 2 15

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without any transformations applied to the responses, and all of the data was used for further analysis.

Table.2. Experimental values Run

No

Table Speed (V)

(m/min)

Wheel speed (N) (RPM)

Depth of cut (d)

(µₘ)

Ra (µₘ)

MRR (g/min)

1 12 550 4.67 0.21 0.9807

2 15 825 2.37 0.22 0.5214

3 12 825.5 4.65 0.53 2.4645

4 6 825 1.75 0.54 0.945

5 12 1025 1.98 0.32 0.6336

6 13 649 2.54 0.41 1.0414

7 14 890 1.12 0.26 0.2912

8 11 990 1.34 0.28 0.3752

9 12 768 1.45 0.62 0.899

The AE signal and the loading total over through the grinding wheel surface rise substantially and remain fairly stagnant throughout the first stage of grinding, and the work piece's grinding efficiency gains. The material removal volume was validated by measuring the measured surface roughness Ra, the measured AE signals, and the measured wheel loading.

The determined surface roughness Ra is sampled ten times in these statistics, and the mean value is taken.

Fig.5.Carbon Steel Plate Re-Grinding Machine for Automatic Flour

As it could be observed, the calculated surface roughness Ra remains constant (between 0.38 and 0.58 m) through the first stage of grinding. The determined surface roughness Ra increases rapidly with the material removal volume at the final stage of grinding (between 0.58 and 0.82 m). It could be because the grinding wheel's ability to grind is deteriorating as a result of detached chips collecting on the surface and waste affecting grinding accuracy. As a result, the work piece's very next grinding efficiency is higher than the final-stage grinding efficiency.

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Fig.6. Material removal rate 7. Conclusion

This work was successful in developing a more efficient domestic grinding machine, achieving an efficiency of 89.2 percent. The machine was put to the test, and it was discovered to be capable of extracting cast-iron metallic particles from the ground product.

Small-scale producers can use the machine because of its low fabrication cost. This was also done in accordance with Nigerian government policy on technical advancement and economic diversification. The domestic pepper grinding machine was developed, built, and tested using (cayenne) dried pepper with a moisture content of about 0%. The following inference can be taken from the output results.

1) Cast-iron metallic particles can be removed from ground powder pepper using the grinder.

2) A dried grinded pepper with a variable pepper dimension and approximately zero moisture content was achieved.

3) In terms of component size and weight, the unit is simpler to maintain than previous models.

4) In terms of removing cast-iron metallic particles, perfect operational reliability is achieved.

To summarize, purchasing a domestic grinding machine is less expensive than purchasing one manufactured locally or abroad.

References

[01] H. Adibi, S. M. Rezaei& Ahmed A. D. Sarhan, ―Analytical modelling of grinding wheel loading phenomena ‖, International Journal of Advance Manufacturing Technology, (2013) 68:473–485.

[02] N. Alagumurthi, K. Palaniradja& V. Soundararajan, ―Heat generation and heat transfer in cylindrical grinding process – a Numerical study‖, International Journal of Advance Manufacturing Technology, (2007) 34:474–482.

[03] R. Deiva Nathan, L. Vijayaraghavan, R. Krishnamurthy, “In-process monitoring of grinding burn in the cylindrical grinding of Steel”, Journal of Materials Processing Technology 91 (1999) 37–42.

[04] K. Salonitis& T. Chondros& G. Chryssolouris, ―Grinding wheel effect in the grind- hardening process‖, International Journal of Advanced Manufacturing Technology (2008), 38:48–58.

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[06] M. Dauda. And C. Okechuku, (2013): Development of a diameter model for the determination of the equivalent lengths of composite shafts. The International Journal of Engineering and Science (IJES), Vol.:2, PP.46-51.

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Experimental and Numerical Analysis of the Surface Integrity resulting from Outer-Diameter Grind.

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