UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Study Performance of Cylindrical

Grinding On Straightness

Thesis submitted in accordance with the partial requirement of the

Universiti Teknikal Malaysia Melaka for the Degree of Bachelor of Manufacturing
Engineering (Manufacturing Process) with Honours

BY

MOHD AFFENDY BIN SAMDIN

Faculty of Manufacturing Engineering

May 2008
 UTeM Library (Pind.1/2007)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PSM

JUDUL:
STUDY PERFORMANCE OF CYLINDRICAL GRINDING ON STRAIGHTNESS

SESI PENGAJIAN:
SEMESTER 1 & 2 2007/2008

Saya MOHD AFFENDY BIN SAMDIN

mengaku membenarkan laporan PSM / tesis (Sarjana/Doktor Falsafah) ini disimpan
di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat
kegunaan seperti berikut:
1. Laporan PSM / tesis adalah hak milik Universiti Teknikal Malaysia Melaka dan
penulis.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis.
3. Perpustakaan dibenarkan membuat salinan laporan PSM / tesis ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
4. *Sila tandakan (√)
(Mengandungi maklumat yang berdarjah keselamatan atau
SULIT kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA
RASMI 1972)

TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh

organisasi/badan di mana penyelidikan dijalankan)

TIDAK TERHAD

(TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)

Alamat Tetap:
Cop Rasmi:
NO. 34, KG. KEPALA BENDANG,
06200 KEPALA BATAS,
ALOR STAR, KEDAH.

Tarikh: _______________________ Tarikh: _______________________

* Jika laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak organisasi berkenaan
dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.
 DECLARATION

I hereby declare that this report entitled “STUDY PERFORMANCE OF

CYLINDRICAL GRINDING ON STRAIGHTNESS” is the result of my own
research except as cited in the references.

Signature :
Author’s Name : MOHD AFFENDY BIN SAMDIN
Date :

iii
 APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a

partial fulfillment of the requirements for the degree of Bachelor of Manufacturing
Engineering (Manufacturing Process) with Honours. The members of the supervisory
committee are as follow:

MOHD AMRI BIN SULAIMAN

Main Supervisor
(Official Stamp & Date)

iv
 ABSTRACT

Main goal through this project is to have the deeply knowledge to the performance of
cylindrical grinding on straightness of the specimen, an experimental investigations were
planned with machining difference type of specimen materials. Detail studies were been
done for the speed of grinding cutting, feed rate, type of specimen material that were use,
and table speed. Attempts were made to mild steel and stainless steel with difference of
strength to get the result. The objective of the project is to expose the students about the
knowledge to identify machine part and performance of cylindrical grinding conventional
machine. These projects are also including machine operating training session in order to
make student easily understand the machine principle to produce full report writing, slide
presentation and report during this project. The studies also concern the student capability
through process and maintenance. All data will be evaluated done from the project lab result.
The performance of the cylindrical grinding machine were related with all parameter,
material structure, coolant type, machine alignment and procedure used. Lastly, after getting
the result, conclusion will be able to make for complete the report. The conclusion explains
about the problems occurs and problem solving.

v
 ABSTRAK

Matlamat utama projek ini adalah untuk mendapatkan pengetahuan yang lebih mendalam
mengenai perlaksanaan mesin pengisar membulat terhadap kelurusan bahan kajian melalui
penggunaan jenis bahan kerja yang berbeza. Kajian terperinci dijalankan terhadap kelajuan
mengisar, kedalaman suapan, jenis bahan kerja yang digunakan serta kelajuan pergerakan
meja mesin. Percubaan dijalankan ke atas keluli lembut dan keluli tahan karat yang
mempunyi perbezaan kekuatan untuk mendapatkan keputusan kajian. Tujuan projek ini
adalah untuk memberikan pendedahan pengetahuan kepada pelajar untuk mengenal pasti
bahagian-bahagian mesin dan perlaksanaan oleh mesin pengisar membulat biasa. Sesi latihan
mengoperasikan mesin juga turut disertakan bagi memudahkan pelajar lebih memahami
prinsip pengoperasian mesin serta menyediakan laporan dan membuat perbentangan untuk
projek ini. Kajian juga berkenaan kebolehupayaan pelajar melalui kerja penjagaan mesin.
Setiap keputusan akan dinilai melalui data dari kajian yang dijalankan. Persembahan mesin
pengisar adalah berhubung kait dengan parameter, struktur bahan kajian, jenis cecair
penyejuk, penjajaran mesin, dan kaedah yang digunakan. Akhir sekali, setelah mendapat
keputusan, kesimpulan dapat dibuat untuk melengkapkan laporan. Kesimpulan menerangkan
permasalahan yang timbul dan penyelesaian masalah.

vi
 DEDICATION

Special thanks I dedicate to my beloved family especially for my father (Samdin bin Ali) and
my mother (Pauziyah binti Abd. Ghani). Thanks for all your love and support. I also would
like to say thanks to all my friends and class mate for contributing to the success of my
project. The successful of this project cannot be achieved without all of you. Once again,
thank you to all for ever thing.

vii
 ACKNOWLEDGEMENTS

ALHAMDULILLAH, thanks to Allah the Almighty God for giving me strength and patience
to work on my final year thesis project. I would like to take this opportunity to express my
sincere and deepest gratitude to my PSM supervisor Mr Mohd Amri Sulaiman, for his
guidance and opinion in the cause of completing this report. My greatest thanks to my
beloved family for their prayers, support and encouragement throughout this entire period of
this project.

I also would like to convey my biggest thanks to all UTeM staff especially to all staff at
manufacturing department for supporting me throughout my PSM Project. The knowledge
and experience I gained from you all will not be forgotten. I’m also obliged to everyone who
had directly and indirectly involve through contributions of ideas, as well as materials and
professional opinions.

Last but not least, thank you very much especially to UTeM for giving me this kind of
chances. Many of my projects would not be completed successfully without their help.
Thank You.

viii
 TABLE OF CONTENTS

Declaration iii
Approval iv
Abstract v
Abstrak vi
Dedication vii
Acknowledgements viii
Table of Contents ix
List of Figures xiii
List of Tables xv
List of Abbreviations, Symbols, Specialized Nomenclature xvi
List of Appendices xvii

1. INTRODUCTION 1
1.1 Background of Project 1
1.2 Problem Statement 2
1.3 Objectives 2
1.4 Scope Project 3

2. LITERATURE REVIEW 4
2.1 Introduction to Cylindrical Grinding Machines 4
2.2 Types of Machine 5
2.2.1 Plain cylindrical grinding machine 6
2.2.2 Universal cylindrical grinding machine 7
2.2.3 Internal Grinding Machine 8
2.3 Machine Specification 9
2.4 Cylindrical Grinding Machine Part 11
2.4.1 Tailstock 11
2.4.2 Headstock 12

viii
 2.4.3 Wheel head 13
2.4.4 Grinding Wheel 14
2.4.5 Grinding Wheel Specification 16
2.4.5.1Abrasives 16
2.4.5.2Wheel Markings 17
2.4.5.3Wheel Shapes and Sizes 19
2.4.5.4Selecting the Grinding Wheel 20
2.5 Cylindrical Grinding Cycles 21
2.6 Cylindrical Grinding Operations 21
2.7 Cylindrical Grinding Work Speed 22
2.7.1 Correct Work Speed 22
2.7.2 Rules for Work Speed 23
2.8 Cylindrical Grinding Traverse Speed 23
2.9 Raw Material Selection 25
2.9.1 Mild Steel SS400 25
2.9.2 Stainless Steel SUS 304 27
2.9.2.1 Composition 29
2.9.2.2 Mechanical Properties 30
2.10 Straightness 30
2.10.1 Straightness Factor on Cylindrical Material 31
2.10.2 Cylindricity and Straightness of a Median Line 31
2.10.3 MarForm MMQ44 Formtester 33
2.10.3.1Machines Description 34
2.11 Introduction to Design Of Experiments (DOE) 36
2.11.1 Classical and Taguchi Experiments 36
2.11.2 Choice of Optimum Results 38

3. METHODOLOGY 39
3.1 Introduction 39
3.2 Project Process Planning 40
3.2.1 Machining Introduction 43
ix
 3.3 Machining Parameters Setup 44
3.3.1 Parameter setting 44
3.3.2 Identification of the control factors and their level 44
3.4 Machining Samples 48
3.4.1 Machine Preparation before Machining Using Cylindrical Grinding 48
Machine
3.4.2 Machining Workpiece Using Cylindrical Grinding Machine 50
3.5 Measure and Analysis Data 51
3.5.1 Procedure to Operate MarForm MMQ 44 Formtester Machine 52
3.6 Result & Analysis 56
3.7 Discussion 56
3.7 Conclusion 56

4. RESULTS & ANALYSIS 50

4.1 Introduction 57
4.2 Findings and Result of Straightness 58
4.3 Analysis for Factorial Design Experiment for Mild Steel SS400 59
4.3.1 Significant Parameter of Straightness for Mild Steel SS400 59
4.3.2 Normal Probability Plot of Effects on Straightness for Mild Steel SS400 60
4.3.3 Pareto Chart of the Effects on Straightness for Mild Steel SS400 61
4.3.4 Main Effects Plot on Straightness for Mild Steel SS400 62
4.3.5 Interaction between Parameters on Straightness for Mild Steel SS400 63
4.3.6 Mathematical Model Development on Straightness for Mild Steel SS400 65
4.4 Analysis for Factorial Design Experiment for Stainless Steel SUS304 67
4.4.1 Significant Parameter of Straightness for Stainless Steel SUS304 67
4.4.2 Normal Probability Plot of Effects on Straightness for Stainless 68
Steel SUS304
4.4.3 Pareto Chart of the Effects on Straightness for Stainless Steel SUS304 69
4.4.4 Main Effects Plot on Straightness for Stainless Steel SUS304 70
4.4.5 Interaction Plot (Data Means) on Straightness for Stainless 71

x
 Steel SUS304
4.4.6 Mathematical Model Development on Straightness for Stainless 73
Steel SUS304
5. DISCUSSION 74
5.1 Introduction 74
5.2 Influences in Grinding Operation 74
5.2.1 The Straightness Influence factor by Work Head speed 75
5.2.2 The Straightness Influence factor by Traverse Length 75
5.2.3 The Straightness Influence factor by Depth of cut (wheel infeed) 76
5.3 Influence in Types of Material 76
5.4 Influence in Method of Measurement 76
5.5 Problems Encounter for the Study 77

6. CONCLUSIONS
6.1 Conclusions 78
6.2 Recommendations for Future Research 80

7. REFERENCES 81

APPENDICES

A Straightness Measurement Result

B Analysis of Variance Table

xi
 LIST OF FIGURES

2.1 Plain Cylindrical Grinding Machine 6

2.2 Universal Grinding Machine Showing Operating Controls and 7
Principal Parts
2.3 Universal Cylindrical Grinding Machine Model OD-618 H/S 8
2.4 Internal Grinding Machine 9
2.5 The Tail Stock Position on Cylindrical Grinding Machine 11
2.6 The Head Stock Position on Cylindrical Grinding Machine 12
2.7 The Grinding Wheel Head Part Assembly 13
2.8 The Grinding Wheel Head 14
2.9 The Standard Marking System Chart 18
2.10(a & b) Abrasive Wheel Standard Marking Used For the Project 18
2.11 Wheel Shapes 20
2.12 Cylindrical Grinding Operations 22
2.13 Step Wear of a Cylindrical Grinding Wheel during Cylindrical 23
Traverse Grinding
2.14 Wear Steps and Sinusoidal Displacement between Tool and 24
Workpiece
2.15 Mild Steel SS400 Raw Material 25
2.16 Stainless Steel SUS 304 Raw Material 27
2.17 The Illustration of Straightness 31
2.18 Cylindricity Tolerance Specification 32
2.19 Straightness of a Median Line Tolerance Specification 32
2.15 MarForm MMQ 44 Formtester to Measure Straightness 35

3.1 Flow chart of Project Methodology 42

3.2 Flow chart of Machining Process Sequences 43
3.3 Workpiece Dimension 48
3.4 Band Saw Machine 49

xiii
3.5 Lathe Machine 49
3.6 Universal Cylindrical Grinding Machine model OD-618 H/S. 51
3.7 MarForm MMQ 44 Formtester to Measure Straightness 52
3.8 Clean specimens sample 53
3.9 Setting the Centering and Tilting Parameters 54
3.10 Running the Centering and Tilting Operations 55
3.11 Graphical User Interface (GUI) of FORM PC software 55

4.1 Analysis result of Straightness versus Work Head Speed, Traverse 59

Speed and Depth of Cut Mild Steel SS400
4.2 Normal Probability Plot of Effects on Straightness for Mild Steel 60
SS400
4.3 Pareto Chart of the Effects on Straightness for Mild Steel SS400 61
4.4 Main Effects plot on Straightness for Mild Steel SS400 62
4.5 Interaction Plot between Work Head Speed, Traverse Speed and 63
Depth of Cut for Mild Steel SS400
4.6 Analysis result of Straightness versus Work Head Speed, Traverse 67
Speed and Depth of Cut Stainless Steel SUS304
4.7 Normal probability plot of effects on Straightness for Stainless 68
Steel SUS304
4.8 Pareto Chart of the Effects on Straightness for Stainless Steel 69
SUS304
4.9 Main Effects plot on Straightness for Stainless Steel SUS304 70
4.10 Interaction Plot between Work Head Speed, Traverse Speed and 71
Depth of Cut for Stainless Steel SUS304.

xiv
 LIST OF TABLES

2.1 Machine Specification 9

2.2 Mechanical Properties of Grade Mild Steel SS400 26
2.3 Composition Ranges for Grade Stainless Steel SUS304 29
2.4 Mechanical Properties of Grade Stainless Steel SUS304 30
2.5 Eight-Run Classical Arrays 37
2.6 Eight-Run Taguchi Arrays 37

3.1 Gantt chart of Projek Sarjana Muda 1 40

3.2 Gantt chart of Projek Sarjana Muda 2 41
3.3 The Level of Process Parameter for Cylindrical Grinding Machine 44
3.3 Orthogonal Array Table for Result taken 45
3.4 Orthogonal Array Table for Experiment using Mild Steel SS400 46
3.5 Orthogonal Array Table for Experiment using Stainless Steel SUS304 47

4.1 Experimental result on Straightness for Mild Steel SS400 58

4.2 Mean Value of Straightness for Mild Steel SS400 for each 2- Way 64
Interaction
4.3 Estimated Effects and Coefficients for Straightness of Mild Steel SS400 65
(coded units)
4.4 Experimental result on Straightness for Stainless Steel SUS304 66
4.5 Mean value of straightness for Stainless Steel SUS304 for each 2- way 72
interaction
4.6 Estimated effects and coefficients for straightness of Stainless Steel 73
SUS304 (coded units)

xv
 LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED
NOMENCLATURE

CNC - Computer Numerical Control

DOE - Design of Experiment
FKP - Fakulti Kejuruteraan Pembuatan
PSM - Projek Sarjana Muda
UTeM - Universiti Teknikal Malaysia Melaka
In/min - Inch per Minute
rpm - Revolution per Minute
µm - Micron Meter
mm - Millimeter
Ls - Length of ground dimension on workpiece, in.
Ts - Total rough or finish stock depth removed from diameter, in.
D - Original workpiece diameter, in.
W - Wheel width, in.
P - Traverse for each work revolution in fraction of wheel width
fi - Infeed of wheel per pass, in./pass
v - Workpiece peripheral velocity, in. /min
PS - Manufacturer’s symbol indicating exact kind of abrasive
A - Aluminum Oxide
80 - Abrasive Grain size; 80 in fine grain size
K - Grade; K is in medium grade.
8 - The wheel structure
V - Bond type; V for vitrified
6N - Manufacturer’s private marking to identify wheel

xvi
 LIST OF APPENDICES

A Straightness Measurement Result

B Analysis of Variance Table

xvii
 CHAPTER 1
INTRODUCTION

1.1 Background of Project

As one of the many tools available to manufacturing, grinding is a distinctive technology

that uses abrasives or synthetic minerals in loose or bonded form. Grinding is one of most
important technologies used by manufacturing today. Used to machine and finish materials,
grinding is in many cases the only method available to engineers, particularly when ceramic
or new composite materials are involved. In other cases, grinding competes with other
technologies and offers the most economical way to produce precision component. As
compared with other machining processes, grinding is a costly operation that should be
utilized under optimal conditions.

Grinding is a finishing process used to improve surface finish, abrade hard materials, and
tighten the tolerance on flat and cylindrical surfaces by removing a small amount of material.
In grinding, an abrasive material rubs against the metal part and removes tiny pieces of
material. The abrasive material is typically on the surface of a wheel or belt and abrades
material in a way similar to sanding. On a microscopic scale, the chip formation in grinding
is the same as that found in other machining processes. The abrasive action of grinding
generates excessive heat so that flooding of the cutting area with fluid is necessary.

1
In Faculty of Manufacturing Laboratory in Universiti Teknikal Malaysia Melaka there were
new types of machine called Cylindrical grinding machine. Hence, this report is mainly
purpose to cover the study of performance of the cylindrical grinding. This study also to
determine the machine capability in term of producing high accuracy and precision, the
highly product finishing that can influence by straightness to the product.

1.2 Problem Statement

i. Cylindrical grinding machine is a new machine in FKP laboratory.

Thereby, student does not have any experience of handling the machine.
ii. Student does not know the machine performance because there is no
machining has done before.
iii. This study will develop the appropriate parameter for cylindrical grinding
machining that can practice for the student.

1.3 Objectives

i. To study the performance of Cylindrical Grinding machine in FKP

Laboratory
ii. To analyzed the straightness factor of the finish product using Mahr
Formtester MMQ44 at the university Metrology Lab.
iii. To determine relationship between parameters and term of straightness
factor.
iv. To expose student how to research environment such as Design Of
Experiment (DOE) and others.

2
1.4 Scope Project

The scope of this project is to handling an appropriate machining operation by using the
cylindrical grinding machine to study the machine performance in term of straightness
factor. The Universal Cylindrical Grinder Model OD618S will be used in the study is. The
material used for machining is mild steel SS400 and stainless steel SUS 304. The parameters
that involve in this analysis are work head speed, depth of cut, and traverse speed are set
followed to the design of experiment (DOE). Parameters such as coolant which is Pretech
Cool Syn 3000 Green with a 1-3% of viscosity and abrasive wheel speed are constant. The
straightness test for the specimen will be test or conduct by using the Mahr Formtester
MMQ44 at the Metrology Lab and method that is will be applied to determine the
straightness.

3
 CHAPTER 2
LITERATURE REVIEW

2.1 Introduction to Cylindrical Grinding Machines

Grinding machines finish parts having cylindrical, flat, or internal surfaces. The surface of
the parts largely selects the grinding machines. A machine grinding cylindrical surfaces is
called a cylindrical grinder. Machines designed for special functions, such as tool grinding or
cutting off, are designated according to their operation. [13]

Cylindrical grinding machines were used extensively in engineering workshops and

industries for finish pre-machined and heat-treated components. Grinders can rough out and
finish the work to fine tolerances. The surface and great accuracy can be obtained more
economically on grinders than other machines.

In Manufacturing Laboratory, the machine that were use for this studies is conventional
Universal Cylindrical Grinder Model OD 618H/S, with variable speed table and manual
wheel head in feed manufactured by SHARP Precision Machine Tools. The machine has the
capability to machine both of internal and external cylindrical grinding.

In the cylindrical grinding machine, the work piece is supported and rotated between centres.
The head stock provides the low-speed rotational drive to the work piece and is mounted,
together with the tail stock on a work table that reciprocated horizontally using the hydraulic
drive. The grinding-wheel spindle is horizontal and parallel to the axis of work piece
rotation, and horizontal, hydraulic feed can be applied to the wheel head in a direction
normal to the axis of work piece rotation; this motion known as in feed.
4
A cylindrical surface being generated using the traverse motion; an operation that can be
linked to cylindrical to cylindrical turning where the single point cutting tool is replace by a
grinding wheel. [13]

The cylindrical grinder traverses the work, to and fro, in repeated passes along the length of
the diameter, and the time to traverse is found using [18]:

time /pass = Ls x Ts x D
(WP) 2fi v

Where;

Ls = Length of ground dimension on workpiece, in.

Ts = Total rough or finish stock depth removed from diameter, in.
D = Original workpiece diameter, in.
W = Wheel width, in.
P = Traverse for each work revolution in fraction of wheel width
fi = Infeed of wheel per pass, in./pass
v = Workpiece peripheral velocity, in. /min

2.2 Types of Machine

Cylindrical grinding machines are used extensively in .engineering workshops to finish pre-
machined and heat-treated components. Grinders can rough out and finish the work to fine
tolerances. The surface finishes and great accuracy can be obtained more economically
grinders than on other machines.

5
 (a) The four types of cylindrical grinders are:
i. Plain cylindrical grinding machine
ii. Universal cylindrical grinding machine
iii. Internal grinding machine
iv. Centreless grinding machine

2.2.1 Plain Cylindrical Grinding Machine

This machine is used for grinding parallel, tapered, stepped or formed external cylindrical
surfaces. They were originally designed for finishing hardened work, but their operation
efficient that they are now used for finishing most types of metals and materials.

Figure 2.1: Plain Cylindrical Grinding Machine

6
 Figure 2.2: Universal Grinding Machine Showing Operating Controls
and Principal Parts

2.2.2 Universal Cylindrical Grinding Machine

The universal grinding machine is very similar in construction to a plain grinding machine,
except for the work head and the wheel head, both of which swivel. The work head swivels
on a graduated base to 100 either side of zero. The wheel head platen not only swivels
through 180° either side of zero, but is also mounted on a slide that swivels independently
through 800 to 90° either side of zero. Thus, the slide can be set to the grinding angle
required, and the platen swivelled through 90° presenting the wheel/face parallel to the face
to be ground. A semi-universal machine in common use is very similar, except that the
wheel platen and slide do not swivel independently of each other.