Research Papers

Role of Temperature Parameters in Achieving Precision Traverse Cylindrical Grinding of Chrome-Plated Ferrous Metal Rolls

[+] Author and Article Information
Ellis Taylor

Department of Mechanical Engineering,
The University of Sheffield,
Mappin Street,
Sheffield S1 3JD, UK
e-mail: ellis.taylor@sheffield.ac.uk

Tom Slatter

Department of Mechanical Engineering,
The University of Sheffield,
Mappin Street,
Sheffield S1 3JD, UK
e-mail: tom.slatter@sheffield.ac.uk

1Corresponding author.

Manuscript received March 31, 2017; final manuscript received September 8, 2017; published online November 2, 2017. Assoc. Editor: Xun Chen.

J. Manuf. Sci. Eng 139(12), 121012 (Nov 02, 2017) (10 pages) Paper No: MANU-17-1204; doi: 10.1115/1.4037889 History: Received March 31, 2017; Revised September 08, 2017

This work considered the finishing precision grinding process at a small ferrous metal roll manufacturer. A design of experiments (DOE) methodology was used to evaluate the process and ascertain whether the degree of confidence gained from the process offers an acceptable level of risk in the conformance of end products to customer requirements. A thorough identification of the process variables and measurement considerations relevant to the process was carried out, before assessing and categorizing these variables using the grinding cycle as a “black box” system. Coolant temperature, environment temperature, work speed, and traverse speed were all considered against measured size change, surface finish, and circular run-out in a full factorial experimental design. The experiments were carried out on a manual cylindrical grinding machine retrofitted with digital encoders on the driven axes, with a chrome-plated roll 300 mm in diameter as the workpiece. Experiments were conducted over a period of 11 months during which the machine used was part of ongoing production environment. The results show that control of temperature, both of the coolant and of the environment in which the machine was operated, was the most important of the variables studied, but the skill of the machine operator remains dominant in the process overall.

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Fig. 1

Grinding process used in this work

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Fig. 2

Experimental run combinations used

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Fig. 3

Setup of chrome test roller between centers

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Fig. 4

Probe placement and measurement positions schematic

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Fig. 5

Illustration of the correct probe placement

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Fig. 6

Workpiece diameter and change in roll diameter after each run

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Fig. 7

(a) Pareto (α = 0.05) and (b) main effects chart for size change

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Fig. 8

Circular run-out measurements made and the changes between them for each run

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Fig. 9

(a) Pareto (α = 0.05) and (b) main effects chart for the run-out

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Fig. 10

Surface roughness for each run and the change in the surface roughness between each run

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Fig. 11

(a) Pareto (α = 0.05) and (b) main effects chart for the surface roughness

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Fig. 12

Temperature data for the period July 2015–June 2016 for measurement room

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Fig. 13

Temperature data for the period July 2015–June 2016 for machine used

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Fig. 14

Mean temperature per month for the north of England, modified from Ref. [12]




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