IDL - International Digital Library Of Technology & Research Volume 1, Issue 3, Apr 2017
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International e-Journal For Technology And Research-2017
Modification Of Existing Machine For Data Automation Of Belt Testing Machine Deepak R 1,Gurudath S N2, Hanumantaraya3,Jeswanth Reddy4,Praveen Kumar S5 UG Student, Department of Mechanical Engineering, NMIT Bangalore, Karnataka, India 1, 2, 3, 4 Assistant Professor, Department of Mechanical Engineering, NMIT Bangalore, Karnataka, India 5
In the manufacturing sector, surface grinding testing machine plays important role. Grinding in this machine parameters to be considered are surface quality and metal removal rate. Several factors which include depth of cut, wheel grade, wheel speed, material properties and table speed affects the machining In belt testing machine we find life of the belt. Also different parameters of belt like cycle timing, power, MRR. During this process of belt testing machine, we find material removal to calculate material removal rate, by using manually weighing method, so to automate material removal rate we proceed with different method. One of our methods is length reduction method. This method can be achieved by distance measuring devices.
imposes less strain on the work piece when compared to other forms of grinding; cracking, burning etc.
Keywords: Grinding testing power, cycle time
Grinding has traditionally been used for metallic materials such as hardened (> 60 Rc) tool steels, tungsten carbide, super alloys used in the aerospace industry, and ceramic materials such as silicon nitride, silicon carbide, alumina, and zirconia. Grinding may also be the fabrication process of choice for several newer and lesser-known classes of materials such as carbon and metallic foams, bulk amorphous metals (metallic glasses), ceramic-magnets, intermetallic, and composite materials. Anyone faced with grinding these materials should be interested in a cost-effective grinding process while maintaining required dimensional tolerances, surface characteristics, and mechanical properties.
Abstract:
machine,
MRR,
1. INTRODUCTION Belt grinding machines achieve rates of high production efficiency, quality finish and economy never realized in any other method of grinding or polishing. For example, by changing grit sizes, a machine may be converted from a heavy duty grinder to a fine micro polisher. Belt grinding machines can be adopted for semi-automatic or fully automatic working. Further, in most applications, belt grinding
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In order to evaluate and optimize product performance, we must focus on the interaction of the grinding product with the entire grinding process. A grinding process is much more difficult to control and optimize than other machining processes such as turning or milling because in grinding there are literally thousands of miniature cutting tools acting on the work piece in a more or less random manner. There are also more process variables in grinding than in most other machining processes, with perhaps a dozen significant variables related to the performance of the grinding product alone.
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IDL - International Digital Library Of Technology & Research Volume 1, Issue 3, Apr 2017
Available at: www.dbpublications.org
International e-Journal For Technology And Research-2017 1.3.4 G-RATIO- It is equal to the normalized MRR’ divided by the normalized BWR’. As a result, this term is dimensionless. It is used in determining the efficiency of the grinding wheel of removing material from the steel. 1.3.5 SGE- Specific grinding energy. It is equal to the total power divided by the material removal rate (MRR). This term is used in understanding how much energy is needed to grind a certain unit of material from the steel. Its units are W min/in3.(1)
Fig 1.1: Belt Testing Machine
1.4EXISTING SYSTEM 1.4.1 DATA COLLECTION IN BELT TESTING MACHINE
Fig1.2: Belts used in Testing Machine
1.3 NOMENCLATURE 1.3.1 MRR’-Material removal rate. This is the normalized rate at which material is removed from the steel during grinding. For our calculations, MRR was normalized so the width of grinding wheel does not have an effect on the MRR used for our calculations. Its units are in 3/min/in. 1.3.2 BWR’- Belt wear rate. This is the normalized rateat which material is removed from the grinding wheel during grinding. For our calculations, BWR was normalized so the width of grinding wheel does not have an effect on the BWR used for our calculations. Its units are in 3/min/in. 1.3.3 UNIT POWER-It is the normalized amount of power that is required to spin the grinding wheel during the grinding process. Its units are W/in.
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Initial belt weight Final belt weight Initial job weight Final job weight Cycle time Power drawn Force (F)
1.4.2 PRESENT COLLECTION
SITUATION
FOR
DATA
1. AUTOMATED DATA The Cycle time- The cycle time is collected in fis file. This fis file is hooked up to spm machine. Fis file is collects automated data and transfers in to the excel sheet. This cycle time is automated. Power- The power (idle) is also collected in fis file. This fis file is hooked up to spm machine. The
geometric power is recorded in fis file. 2. NON AUTOMATED DATA Material removal (MR)-The material removal can determine by taking the difference between the initial
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IDL - International Digital Library Of Technology & Research Volume 1, Issue 3, Apr 2017
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International e-Journal For Technology And Research-2017 weight and final weight of job. The MR is nonautomated
1.5 METHOD OF TESTING BELT PERFORMANCE IN MACHINE 1 OBJECTIVE: To assess the coated abrasive cloth belt product for its performance against a standard/New product coated abrasive cloth belt product. 2 SCOPES: These instructions are applicable products as indicated in the DOC #QAD/CH/01.
The samples have to joint to 2000mm or 3500mm length belt and then slit to 50mm width. Note down all the details mentioned in the test request and fill the data in the belt resting format saved in the computer attached to this machine. Take all the 50 flats (SS304 or CRV), weigh them separately and record the wights in the format saved in the computer. Weigh the belt and note down its weight in the format saved in the computer . Mount the belt on to the tester. Align the belt in running condition using the tracking arrangement provided in the tester.
to 1.6 FLOW CHART
3 APPARATUS: Belt testing machine (50x2000mm or 3500mm belt to mount) having a serrated rubber contact wheel with a pneumatic connection line and with pneumatic cylinder to use as loads. For weighing belt use a weigh scale of 0.2gm. resolution and for weighing the SS304,CRV jobs use a weigh scale of 0.2gm, resolution. 50Nos. SS304/CRV test jobs of lengt135mm with width 12mm (length reduces on usage and hence not a parameter to consider) and thickness of 4mm. 110mmm with width 6mm (length reduces on usage and hence not a parameter to consider) and thickness of 8mm respectively. 4 METHOD: Receive the coated abrasive cloth belts from initiator as per the request. The request can be in any format like written communication, Telephonic call, Fax, E-mail. As per DOC # QAD/CH/01, if the product is to be tested for performance test,
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2.
OBJECTIVES
To automate the material removal rate. Copyright@IDL-2017
IDL - International Digital Library Of Technology & Research Volume 1, Issue 3, Apr 2017
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International e-Journal For Technology And Research-2017
Conduct a detailed study on grinding characteristics of coated abrasive belt grinding process and develop a methodology to maximize the output and usage of belt grinding. Conduct experiments to study the belt properties and grinding parameters to arrive a systematic process to select belt and grinding parameters. Analyze the data and develop statistical model considering individual and interactive parametric influence on performance indicator. Recommend the feasibility of optimizing parameters for custom specific Applica
2.1 AUTOMATE MR The biggest challenge manufactures see in most material removal processes is keeping accuracy and consistency. The difference in a manufacturing process that handles material removal in a consistent and accurate manner can be the difference in tens of thousands of dollars in rejected parts. The best way to ensure this process is accurate and consistent is to integrate material removal automation into your manufacturing process. Our automation design process includes an in-house through examination of your current testing operations. Items such as payload ease of integration, speed, and human errors. 3. METHODOLOGY 3.1 METHOD TO FIND MR
Weight reduction method
Volume reduction method
3.2 EXPERIMENTAL WORK LVDT Working principle
Fig 3.1 LVDT
This MR can automate by taking the reduced length of job and determined the reduced volume of job. The below formula is used to find out the material removal of job. MR=Density of material*reduction volume of job
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IDL - International Digital Library Of Technology & Research Volume 1, Issue 3, Apr 2017
Available at: www.dbpublications.org
International e-Journal For Technology And Research-2017
Fig 3.2 General LVDT Assembly Linear variable differential transformers (LVDT) are used to measure displacement. LVDTs operate on the principle of a transformer. As shown in Figure, an LVDT consists of a coil assembly and a core. The coil assembly is typically mounted to a stationary form, while the core is secured to the object whose position is being measured. The coil assembly consists of three coils of wire wound on the hollow form. A core of permeable material can slide freely through the canter of the form. The inner coil is the primary, which is excited by an AC source as shown. Magnetic flux produced by the primary is coupled to the two secondary coils, inducing an AC voltage in each coil.(2)
Fig 3.3 finding the reduction length by LVDT
3.3 PLACING OF LVDT
Fig: 3.4 layout of belt testing machine
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IDL - International Digital Library Of Technology & Research Volume 1, Issue 3, Apr 2017
Available at: www.dbpublications.org
International e-Journal For Technology And Research-2017
Fig 3.6 Positioning of LVDT 3.4LVDT specification
Fig 3.5 3D model LVDT setup
•
Specifications: Range: 0.01. 0.1, 0.5, 1.0, 2.0, 5 0, 7.5, 10, 25, 50, 100, 150 mm.
•
Resolution: Infinite Linearity: Better than ±0.5%
•
Excitation Voltage: AC Sinusoidal 1V, 4 KHz
•
Sensitivity: 1mV/0.01 mm displacement Construction: Body – Non-Magnetic
•
Stainless steel Core – Ferro-magnetic with non-magnetic stainless steel extension
•
Operating Temperature: 100 to 60°C (4)
3.5 PROCEDURE
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We place LVDT horizontal position to the work piece in rigid position to the carriage of machine. We find out the distance between work piece edges and grind wheel initial. The distance between LVDT needle and obstacle is maintained same distance like work piece and grind wheel. Copyright@IDL-2017
IDL - International Digital Library Of Technology & Research Volume 1, Issue 3, Apr 2017
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International e-Journal For Technology And Research-2017
When the machine is started work piece carriage will move towards grind wheel at the same time correspondingly LVDT also move. When the work piece plunges to grind wheel at the same time LVDT needle will plunge to obstacle. The decreases in the work piece length is noted in the digital indicator of LVDT The value of displacement in the digital indicator (RS-232) is transferred to the fis file in the computer.
5
9.0
22.5
1080
8.44
0.936
6
8.9
21.4
1027.2
8.01
0.902
7
8.8
20
960
7.5
0.85
8
8.9
18
864
6.74
0.757
9
8.9
16.86
809.28
6.31
0.709
10
9.0
16
768
6
0.665 6
Material specification: Material = Chromium -3 Density=7.8*10 kg/mm3
vanadium
Test job=Width*thickness*length =6*8*100 (in mm3)
3.5RESULT AND DISCUSSION 3.5.1CALCULATED MRR USING REDUCTION LENGTH Table 5.2 Cy cle no
Cy
Differ
Volume=
MR=
MRR
cle
ence
width*thick
density*v
=
tim
length
*length
olume
MR/t
(gm)
ime
e
(mm)
3
(mm )
(t)
(gm/
Fig 3.7: MRR v/s cum. time
s) 1
9.0
33
1584
12.35
1.372 8
2
9.0
28.6
1372.8
10.7
1.2
3
9.0
25.8
1238.4
9.7
1.073
4
8.9
24.5
1176
9.17
1.030 6
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steel
IDL - International Digital Library Of Technology & Research Volume 1, Issue 3, Apr 2017
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International e-Journal For Technology And Research-2017 CONCLUSION In belt testing machine time, power is automated where material removal rate is calculated by using weight of work piece. To overcome the issue of manually calculating of MRR, We introduced a reduction volume detection method using LVDT to find the reduction length of work piece From the test we conducted experiment to find material removal from the specimen to know the efficiency of the abrasive belt.
Fig 3.8SGE v/s cum.MR
When we conducted test we got some results that are 4.
IMPLEMENTATION
This is implemented in grinding testing machine LVDt is added to machine It can be implemented in others machines where the length is a factor to find out. A similar investigation can be taken up with much more emphasis on the sensors aspects making it more feasible and requiring in depth measuring properties. The machine is processed with change in length basis for the present; investigation could be made through alternate processing routes such as mass reduction, robotic parts. Belt wear test may be conducted with further variations of parameters such as force applied, pressure, heat produced.
Table 6.1 Comparison between manual v/s automated MRR Sl no.
MRR (Manual calculation)
MRR(Automated calculation)
1
1.378
1.378
2
1.200
1.2
3
1.089
1.073
4
1.056
1.0306
5
0.956
0.936
From above table the results we got are accepted.
REFERENCES 1) Determining material properties Responsible for Grinding performance
5.
OUTCOMES (Benjamin
The theoretical values and practice values are matching It increases efficiency by reducing time During the process it reduces human errors by automating data
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Hall,
Jonathan
king,
Prange) 2) http://www.google.com/patents/US4149409 3)www.saint-gobain.co.in/
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Justin
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International e-Journal For Technology And Research-2017 4) INDUSTRIAL ENGINEERING INSTRUMENTS (www.ieicos.com) 5) Organization of Research Work (XipengXu et al (2003) 6) ) Design and Fabrication of Abrasive Belt Oblique Grinding Machine (A.Robert Henry1, R.Anbazhgan2, A.Kevinraj3, M.Sudhagar4, G.S.Nivas5) 7) Material removal and wheel wear models for robotic grinding wheel profiling (StéphaneAgnarda, ZhaohengLiua,*, Bruce Hazelb) 8) A discussion on the measurement of grinding media wear (Camila Peres Massolaa,∗, Arthur Pinto Chavesb, Eduardo Albertina) 9) Review of test methods for abrasive wear in ore grinding (C. Spero’, D. J. Hargreavesb, R. K. KirkcaIdieband H. J. FlitP) 10) Performance Analysis of Cylindrical Grinding Process with a Portable Diagnostic Tool ( R. Vairamuthu1 , M Brij Bhushan2 , R. Srikanth1 , N. Ramesh Babu3*)
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