International Journal of Scientific Engineering and Technology

Volume No.5 Issue No.4, pp: 188-195

ISSN:2277-1581
01 April 2016

Investigation on MRR and RA of Surface Grinding on EN31

Pardeep Ranga, Er. Deepak Gupta,
AbstractSurface grinding is most common process used in
the manufacturing sector to produce smooth finish on flat
surfaces. Metal removal rateand Surface qualityare the two
important performance characteristics to be considered in
the surface grinding process. The process of grinding is
affected by several factors such as wheel speed, depth of cut,
table speed, material properties and abrasive wheel
grade.The main purpose of this study is to study the effects of
abrasive tools on EN31 steel surface by using three
parameters (Table speed, Depth of cut & Grinding wheel
speed). This study was conducted by using CNC surface
grinding machine at IIT, Delhi. Total series of experiments
performed was 15 set for grinding wheels of Aluminium
Oxide.In this work, empirical models were developed for
Material removal Rate and surface roughness by considering
depth of cut,table speed, wheel speed as control factors using
response surface methodology. In this Response surface
methodology as applied to determine the optimum machining
parameters leading to maximum metal removal rate and
minimum surface roughness in Surface grinding process.
Keywords: CNC Grinding, EN31 steel, Design Expert 6.0,
Material removal rate, surface roughness, Al2O3 wheel, Response
Surface Methodology.
I. INTRODUCTION
Grinding is a material removal process and surface generation
process used to shape and finish components made of metals and
other materials. Grinding is the most common form of abrasive
machining. It is a material cutting process which engages an
abrasive tool whose cutting element are grains of abrasive
material known as grit. These grits are characterized by high hot
hardness, sharp cutting points and chemical stability and wear
resistance. The grits are held together by a suitable bonding
material to give shape of an abrasive tool.
The advantage of using such a process over conventional metal
removal processes are as follows.
The rate of removal of material is much higher than a
traditional file.
The surface finish obtained is obviously much better
than can be obtained through a chisel or a file.
It is very difficult to remove metal from a surface when it
is hardened, and grinding is one of the most practical
solutions in such cases.
A grinding wheel consists of abrasive particles and bonding
materials. The bonding material holds the particles in place and
establishes the shape and structure of the wheel. These two
ingredients, and the way they are fabricated, determine the
parameters of the grinding wheel, which are:
a) Abrasive material.
b) Grain size.
c) Bonding material.
d) Wheel structure.
e) Wheel grade.
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II. LITRATURE REVIEW

M.Janardhan and Dr. A.GopalaKrishna[1]through this paper
they want to prove that cylindrical grinding is one of the
important metal cutting processes used extensively in the
finishing operations. Metal removal rate and surface finish are the
important output responses in the production with respect to
quantity and quality respectively. The Experiments are conducted
on CNC cylindrical grinding machine with L9 Orthogonal array
with input machining variables as work speed, feed rate and depth
of cut. Empirical models are developed using design of
experiments and response surface methodology. The adequacy of
the developed model is tested with ANOVA. The developed
model can be used by the different manufacturing firms to select
right combination of machining parameters to achieve an optimal
metal removal rate (MRR) and surface roughness (Ra).The results
reveals that feed rate, depth of cut are influences predominantly
on the output responses metal removal rate (MRR) and surface
roughness (Ra).The predicted optimal values for MRR, Ra for
Cylindrical grinding process are 62.05g/min and 0.816m
respectively. The results are further confirmed by conducting
confirmation
experiments.K.Kadirgama,
M.M.Rahman,A.R.Ismail and R.A.Bakar[2]In thisstudied the
quality of the surface produced during carbon steel is important as
it influences the performance of the finished part to a great extent.
This paper discusses the optimization of cylindrical grinding
when grinding carbon steel (AISI 1042) and effect of three
variables (work speed, diameter of work piece and depth of cut)
towards surface roughness with aluminum oxide as grinding
wheel. Surrogate modelling was used to minimize the number of
experiments and developed mathematical model to predict
surface roughness hence optimization of cutting variables was
found. This model has been validated by the experimental results
of aluminum oxide grinding. Prediction model show that diameter
of the work piece and work speed effect mostly compare with
depth of cut. The optimum cutting parameters for minimum Ra
are work speed 120 RPM, diameter 18 mm and depth of cut
20m. The theoretical analysis yielded values, which agree
reasonably well with the experimental results.AshishBhateja,
AdityaVarma, AshishKashyap and Bhupinder Singh[3]This
Study is based upon the empirical study which means it is derived
from experiment and observation rather than theory. Main
Objective is to Study the Effect on the Hardness of three Sample
Grades of Tool Steel i.e. EN-31, EN-8, and D3 after Heat
Treatment Processes Such As Annealing, Normalizing, and
Hardening & Tempering. This survey also helps to find out the
place of the work to be carried out i.e. availability of set up,
techniques used for such, estimated time & cost requires for such
study to be carried out for such industrial survey to be carried out
we designed a Survey questioner and selects various places who
offers heat treatment services Ludhiana based. After literature
review and industrial survey aims to prepare heat treatment
performance Index HTPI 2012 which is supposed to be very

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Volume No.5 Issue No.4, pp: 184-187
effective tool for defining the objective function. After selection
of material & heat treatment processes further aims to perform
mechanical & chemical analysis i.e. composition testing of the
three tool steel EN-31, EN-8, and D3 before treatment. After
composition testing aims to do heat treatment processes i.e.
Annealing, Normalizing, and Hardening & Tempering to be
carried on such material & after treatment aims to perform
harness testing on the treated and untreated work samples.
Roshani U. Shingarwade Prof. M. S. Harne[4] In this paper,
reaming operation with two different mineral based cutting fluids
were carried out to determine optimum conditions for surface
roughness during reaming of grey cast iron of grade SAE D7003.
K20 cemented carbide reamer was used as cutting tool. Taguchi
L9 orthogonal array was used for the experiment plan. Spindle
speed, feed rate, reverse feed rate were considered as machining
parameters. Mathematical models for cutting parameters were
obtained from regression analyses to predict values of surface
roughness. S/N ratio and ANOVA analyses were also performed
to identify significant parameters influencing surface roughness.
The test results shows that satisfactory hole quality can be
achieved during reaming by employing high spindle speed, low
feed rate and low reverse feed rate.H. Aouici, MA Yallese, A
Belbah, Mfameur and M Elbah[5]Inthis experimental
investigation was conducted to determine the effects of cutting
conditions on surface roughness and cutting forces in hard turning
of X 38 Cr Mo V 5-1. This steel was hardened at 50 HRC and
machined with CBN tool. This is employed for the manufacture
of helicopter rotor blades and forging dies. Combined effects of
three cutting parameters, namely cutting speed, feed rate and
depth of cut, on the six performance outputs-surface roughness
parameters and cutting force components, are explored by
analysis of variance (ANOVA). Optimal cutting conditions for
each performance level are established. The relationship between
the variables and the technological parameters is determined
through the response surface methodology (RSM), using a
quadratic regression model. Results show how much surface
roughness is mainly influenced by feed rate and cutting speed.
The depth of cut exhibits maximum influence on cutting force
components as compared to the feed rate and cutting
speed.Hemant S. Yadav, Dr. R. K. Shrivastava[6] In this Paper
Researcher the main characteristics of grinding in comparison to
other machining process are the relatively large contact area
between the tool and work piece surface. The major limiting
factor in grinding is thermal damage. The main purpose of
grinding fluid can be categorized into lubrication, cooling,
transportation of chips, cleaning of grinding wheel and
minimizing corrosion. In this paper, the effect of process
parameters such as depth of cut, coolant flow rate and coolant
nozzle angle are taken as variables. The present work aims at
optimizing process parameters to achieve surface quality and high
material removal rate in SAE 8620 steel material. Response
surface method a powerful tool in design of experiments is used
for optimization process.Tejendrasinh S. Raol, Dr. K. G. Dave,
Dharmesh B. Patel, Viral N. Talati[7] The aim of this paper is
to investigate the effect of process parameters on surface
roughness of fused deposition modelling built parts. Rapid
prototyping (RP) refers to a class of technology that can
automatically construct the physical models from computer aided
design (CAD) data. Fused depositionmodelling(FDM) is process
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for developing rapid prototype objects from plastic material by

lying track of semi molten plastic filament on to a platform in a
layer wise manner from bottom to top. Response surface
methodology (RSM) was used to conduct the experiments. The
parameters selected for controlling the process are layer
thickness, part built orientation and raster angle. Surface
roughness of fused deposition modelling built parts is measured
by surface roughness tester. From the results of the experiments,
mathematical model have been developed to study the effect of
process parameters on surface roughness. M. Aravind, Dr. S.
Periyasamy[8] In this study, the surface grinding process
parameters were optimized by using Taguchi method and
Response Surface Methodology (RSM). The process parameters
considered in this study are grinding wheel abrasive grain size,
depth of cut and feed. An AISI 1035 steel square rod of 100 mm x
10 mm x 10 mm was considered for grinding. The output
response was selected as Surface roughness (Ra and Rz). In
Taguchi method, L27 orthogonal array was selected and S/N
ratios were analyzed to study the surface roughness
characteristics. In response surface methodology, Box Behnken
method was used for optimization. Thirteen experiments were
conducted in the surface grinding machine. The surface
roughness values were entered in the Design Expert software and
the optimal solution was obtained. Both methods showed that
wheel grain size and depth of cut influences the surface roughness
a lot. Feed of the surface grinding has a very minimal effect on the
surface roughness value. This study showed that when the input
parameters can be varied within the selected levels, Response
surface methodology has an edge over Taguchi method. The
confirmation experiments were conducted both for the optimal
solution obtained from Taguchi and Response surface
methodology.
III Material Properties
(a) Work piece material: EN 31 steel
(b)EN31 is a high carbon Alloy steel which achieves a high
degree of hardness with compressive strength and abrasion
resistance.
IV. Response Surface Methodology (Rsm)
Response Surface Methodology (RSM) is a collection of
mathematics and statisticaltechniques which is useful for
developing,improving and optimizing processes. It also has
importantapplications in the development, design and
formulation of new products, as well as in the improvement of
existing product designs.The field of RSM consists of the
experimental strategy for exploringthe space of the process or
independent variables, empirical statisticmodelling to develop an
appropriate approximating relationshipbetween the process
variables and optimization methodsfor finding the levels or values
of the process variables that producesdesirable values of the
responses.
V. Machine And Equipments
The following equipments were used in this experimental works:
1 CNC Surface Grinding
Brand : Chevalier
Model : Smart-H1224II
No of axis : 3 axes (X , Y & Z)

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Volume No.5 Issue No.4, pp: 188-195
This CNC Surface Grinding machine was used to produce the
surface grinding on the surface of the EN24 steel at IIT, Delhi.
2 Surface Roughness Tester
Brand: Surf test
Model: SJ-301
Surface roughness of the machined work pieces was measured
using this machine.
3 Electronic Balance
(i)
Brand
: Lakshmi Samson
(ii)
Model : S500
(iii)
Capacity : 500 gram
(iv)
Accuracy: 0.01g
Precision balance was used to measure the weight of the
workpiece before and after the machining process.
VI Design Expert Software 6.0
This software was used for planning experimental design matrix
and analyzing all the response according to statistical method.

Figure1 Specimens before surface finishing

Figure2 Specimens after surface finishing

VII. RESPONSE PARAMETERS
The response parameters include:
1. Material removal rate (MRR)
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2. Surface Roughness (Ra)

VIII. RESULT ANALYSIS
The experimental results of surface finishing of EN31 with Al2O3
wheel are shown in Table 1. The results are keyed in the Design
Expert software for further analysis according to the steps
outlined for two levels half factorial design. Without performing
and transformation on the responses, the revealed design status
was evaluated and all the information was used for further
analysis
Table 1 Experimental observations for Al2O3 wheel
Run
No.

Wheel
speed
(N)
(RPM)

Table
Speed
(V)
(m/min)

Surface
Roughness
( Ra)
(m)

Metal
Removal
Rate
(g/min)

7.50

Depth
of cut
(d)
(m)
5.0

1250

1.03

10.75

1250

10.0

5.0

1.59

13.28

1250

10.0

10.0

1.86

18.35

1250

7.5

10.0

1.18

12.45

1250

12.5

15.0

1.58

25.35

1650

7.5

5.0

1.56

16.35

1650

12.5

5.0

1.44

15.65

1650

7.5

10.0

1.21

22.45

1650

10.0

10.0

1.63

14.15

10

1650

12.5

15.0

1.27

16.45

11

2050

12.5

5.0

1.08

12.45

12

2050

10.0

5.0

1.71

13.75

13

2050

10.0

10.0

1.36

24.25

14

2050

12.5

10.0

1.51

28.25

15

2050

7.5

15.0

1.58

18.35

5.3 Result Analysis

The experimental results for all responses using Al2O3 wheel, Ra
and MRR are tabulated as in Table1.
5.3.1 Effect of process parameters on surface roughness (Ra)
Based on the proposed second-order polynomial model, the effect
of the process variable on the Ra has been determined as follows:
The arithmetic surface roughness value (Ra) was adopted and
measurements were carried out at the left and at the right side and
at the middle of the surface using a Surftest SJ-301. Before
conducting the measurement of Surface Roughness, all the
samples were cleaned with acetone. The Ra values of the surface
were obtained by average of thethe surface roughness.
Design expert 6.0 software has been used to compute the values
as shown in Table1. The developed statistical model for Ra in
coded form is

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Surface Roughness = +1.60 - 0.063 * A - 0.17 * B + 0.98 * C +
0.14 * A * B - 0.49 * A * C - 0.30 * B * C
(1)
Final Ra equation in terms of actual factors is
Surface Roughness= -0.43282 + 5.56984E-004 * Wheel speed
-4.51730E-003 * Table speed + 0.24594 * depth of cut +
3.10669E-005 * Wheel speed * Table speed - 8.98924E-005 *
Wheel speed * depth of cut -4.51180E-003
(3)
From the main effect plots based on the Fig.3 a-c, it has been
observed that whenever wheel speed is increased from 400RPM
to 1100RPM, the value of Ra decreased. The decrement of Ra was
approximately 1.652m to 1.519m. Meanwhile, when table
speed increased from 3m/min to 18m/s Ra decreased from
1.643m to 1.472m and when depth of cut increased from 2m
to 20m Ra increased from 0.75m to 2.36m. In order to obtain
minimum Ra during Surface finishing of EN31 steel using Al2O3
wheel, the optimum parameter combination obtained is wheel
speed = 1600RPM, Table speed = 18m/min, Depth of cut = 2 m.

ISSN:2277-1581
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(c)
Fig. 3- Main factors plot on Ra using Al2O3 wheel
(5.1)
Fig.4 a-bshows the three-dimensional interaction responses
surface and contour plot for the response Ra in terms of table
speed and wheel speed at a depth of cut=11m. Contour plot
plays a very important role in the study of response surface. By
generating
* Table speed
contour
* depth
plot of
using
cut Design expert 6.0 software for the
response surface analysis, it is easy to characterize the shape of
the surface and locate the optimum with reasonable precision.
From the examination of the contour plot and response surface, it
is observed that Ra decreases from 1.60m to 1.54 m with
increase in wheel speed from 1250- 1600RPM with increase of
table speed from 7.5-12.5m/min. Fig. 4d-e shows the
three-dimensional interaction response surface and contour plot
for the response Ra in terms of wheel speed and depth of cut at
table speed of 10.50m/min. It is depicted that the estimated
contour and response surface plot; it is observed that Ra (1.54m
-1.60m) increases with increase of wheel speed and depth of cut.
Fig. 4g-h shows the three-dimensional interaction response
surface and contour plot for the response MRR in terms of table
speed and depth of cut at wheel speed of 1250RPM. It is depicted
that the estimated contour and response surface plot; it is
observed that Ra (1.55m -1.60m) increases with increase of
table speed and depth of cut. In addition, Fig.4j-k displays the
normal probability plot of residuals and residual versus predicted
plots for Ra. It is observed that the residuals generally fall on a
straight line implying that the errors are normally distributed.
Furthermore, this supports adequacy of least squares fit.

(a)

(a)

(b)

(b)
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(c)

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(h)

(d)
(i)
Fig. 4

(e)

Effect of process parameters on material removal rate

Based on the proposed second-order polynomial model, the effect
of the process variable on the MRR has been determined as
follows:
MRR = Wb-Wa (g/min)
(3)
tm
where:
Wb= weight of workpiece material before machining (g)
Wa = weight of workpiece material after machining (g)
tm= machining times (min)
The developed statistical model for MRR in coded form is
Metal Removal Rate = +22.50-25.73 * A+6.72 * B+4.88 *
C+16.09 * A2+48.57 * B2-8.54 * C2 +10.44 * A * B-12.46 * A *
C -10.98 * B * C
(4)

(f)

(g)

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Final equation for MRR in terms of actual factors is

Metal Removal Rate =+157.31495-0.13124 * Wheel
speed-17.76583 * Table speed +6.87820 * depth of
cut+4.46987E-005 * Wheel speed2 +0.86343 * Table speed2
-0.10543 * depth of cut2 +2.31935E-003 * Wheel speed * Table
speed-2.30822E-003 * Wheel speed * depth of cut -0.16266 *
Table speed * depth of cut
(5)
From the main effect plots based on the Fig. 5a-c, it has been
observed that whenever wheel speed is increased from 400RPM
to 1600RPM, the value of MRR decreased significantly. The
decrement of MRR was approximately 64.32g/min to
10.75g/min. Meanwhile, when table speed increased from
3m/min to 18m/min and depth of cut increased from 2m to
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20m showed the most significant effect on MRR i.e 40.0g/min
to 65.0g/min and 7.2g/min to 10.12g/min. In order to obtain better
MRR during Surface finishing of EN31 steel using Al2O3 wheel,
the optimum parameter combination obtained is wheel speed =
400RPM, Table speed = 18m/min, Depth of cut = 11m.

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table speed of 10.5m/min. It is depicted that the estimated contour

and response surface plot; it is observed that MRR
(7.5g/min-14.5g/min) increases with increase of depth of cut and
wheel speed. Fig. 6g-h shows the three-dimensional interaction
response surface and contour plot for the response MRR in terms
of table speed and depth of cut at wheel speed of 1250RPM. It is
depicted that the estimated contour and response surface plot; it is
observed that MRR (9.24g/min-21.24g/min) increases with
increase of table speed and depth of cut. In addition Fig. 6j-k
displays the normal probability plot of residuals and residuals
versus predicted plots for MRR. It is observed that the residuals
generally fall on a straight line implying that the errors are
normally distributed. Furthermore, this supports adequacy of least
squares fit.

(a)

(b)

(a)

(c)

(b)

Fig. 5 Main factors plot on MRR using Al2O3 wheel

Fig.5a-bshows the three-dimensional interaction response surface
and contour plot for the response MRR in terms ofwheel speed
and table speed at a depth of cut=11m. Contour plot plays a very
important role in the study of response surface. By generating
contour plot using Design expert 6.0 software for the response
surface analysis, it is easy to characterize the shape of the surface
and locate the optimum with reasonable precision. From the
examination of the contour plot and response surface, it is
observed that MRR increases from 12.50g/min to 20.97g/min
with increase in wheel speed from 1250- 1600RPM with increase
of table speed from 7.5-12.5m/min. Fig.6d-e shows the
three-dimensional interaction response surface and contour plot
for the response MRR in terms of wheel speed and depth of cut at
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(c)

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ISSN:2277-1581
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(h)
Fig. 6

(d)
7.1 Conclusions

(e)

(f)

In this study, the surface roughness and MRR in Surface finishing

process of EN31 steel using Al2O3 wheel were modeled and
analyzed through RSM. Wheel speed, Table speed and Depth of
cut have been employed to carry out the experimental study.
Summarizing the main features, the following conclusions could
be drawn
1.
t has been observed that whenever wheel speed is increased from
400RPM to 1100RPM, the value of Ra decreased. The decrement
of Ra was approximately 1.652m to 1.519m. Meanwhile, when
table speed increased from 3m/min to 18m/s Ra decreased from
1.643m to 1.472m and when depth of cut increased from 2m
to 20m Ra increased from 0.75m to 2.36m. In order to obtain
minimum Ra during Surface finishing of EN31 steel using Al2O3
wheel, the optimum parameter combination obtained is wheel
speed = 1600RPM, Table speed = 18m/min, Depth of cut = 2 m.
2. It has been observed that whenever wheel speed is
increased from 400RPM to 1600RPM, the value of MRR
decreased significantly. The decrement of MRR was
approximately 64.32g/min to 10.75g/min. Meanwhile, when table
speed increased from 3m/min to 18m/min and depth of cut
increased from 2m to 20m showed the most significant effect
on MRR i.e 40.0g/min to 65.0g/min and 7.2g/min to 10.12g/min.
In order to obtain better MRR during Surface finishing of EN31
steel using Al2O3 wheel, the optimum parameter combination
obtained is wheel speed = 400RPM, Table speed = 18m/min,
Depth of cut = 11m.
3. The predicted values match the experimental values
reasonably well, with R2 of 0.8748 for Surface Roughness, R2 of
0.9539 for MRR.
4. The error between experimental and predicted values at
the optimal combination of parameter settings for MRR and Ra
lie within 4.45% and 4.00%, respectively.
5. From the multi-response optimization, the optimal
combination of parameter settings are wheel speed of 548RPM,
Table speed of 5m/min and Depth of cut of 5m for achieving the
required maximum MRR and minimum surface roughness.

References
(g)
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i. M.Janardhan and Dr.A.Gopala Krishna (2011), Determination

and optimization of cylindrical grinding process parameters using

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International Journal of Scientific Engineering and Technology

Volume No.5 Issue No.4, pp: 184-187
taguchi method and regression analysis. International Journal of
Engineering Science and Technology, vol.3, 5659-5665.
ii. K.Kadirgama, M.M.Rahman, A.R.Ismail and R.A.Bakar(2012),A
surrogate modelling to predict surface roughness and surface texture
when grinding AISI 1042 carbon steel. Scientific Research and Essays,
Vol. 7(5), 598-608.
iii. AshishBhateja, AdityaVarma, AshishKashyap and Bhupinder
Singh (2012), Study the Effect on the Hardness of three Sample Grades of
Tool Steel i.e. EN-31, EN-8, and D3 after Heat Treatment Processes
Such As Annealing, Normalizing, and Hardening & Tempering. The
International Journal of Engineering and Science (IJES) Volume 1Issue
2 Pages 253-259.
iv. Roshani U. Shingarwade Prof. M. S. Harne (2013), Effect Of
Reaming Process Parameters On Surface Roughness Using Taguchi
Method, International Journal of Engineering Research & Technology
(IJERT) Vol. 2 Issue 4, ISSN: 2278-0181
v. H. Aouici, MA Yallese, A Belbah, Mfameur and M Elbah, (2013)
Experimental investigation of cutting parameters influence on surface
roughness and cutting forces in hard turning of X38CrMoV5-1 with CBN
tool, Sadhana Vol. 38, Part 3, June 2013, pp. 429445. Indian Academy
of Sciences
vi. Hemant S. Yadav, Dr. R. K. Shrivastava (2014) Effect of Process
Parameters on Surface Roughness and Mrr in Cylindrical Grinding
using Response Surface Method, International Journal of Engineering
Research & Technology (IJERT), Vol. 3 Issue 3, ISSN: 2278-0181.
vii. Tejendrasinh S. Raol, Dr. K. G. Dave, Dharmesh B. Patel, Viral N.
Talati (2014) An Experimental Investigation of Effect of Process
Parameters on Surface Roughness of Fused Deposition Modeling Built
Parts, International Journal of Engineering Research & Technology
(IJERT) Vol. 3 Issue 4 ISSN: 2278-0181.
viii. M. Aravind, Dr. S. Periyasamy (2014) Optimization of Surface
Grinding Process Parameters By Taguchi Method And Response Surface
Methodology International Journal of Engineering Research &
Technology (IJERT) Vol.3 Issue 5, ISSN: 2278-0181

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ISSN:2277-1581
01 April 2016
Author details:PardeepRanga received his B.Tech
in Mechanical engineering from
Haryana college of technology and
management, kaithal (Haryana),
affiliated to kurukshetra university,
kurukshetra in 2009.
E.Mail- Pardeepranga25@gmail.com
Phone No. +91-9873333825
Guide details:-

doi : 10.17950/ijset/v5s4/406

Er. Deepak Gupta, working as an Assistant

Professor in Galaxy Global Group of
Institutions, Dinarpur, Ambala (Haryana)
affliated
to
kurukshetra
university,
kurukshetra. He received his Master Degree
from Maharishi Markandeshwar University,
Mullana (Haryana) in 2010, He has been
teaching last 9 years,
E-Mail:- Deepakgupta1541@gmail.com.
Phone No.:- +91-9996164702

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