TABLE OF CONTENTS
CHAPTER
DECLARATION
TITLE
DEDICATION
ACKNOWLEDGEMENTS
ABSTRACT
ABSTRAK
TABLE OF CONTENTS
LIST OF TABLES
LIST OF FIGURES
LIST OF ABBREVIATIONS AND SYMBOLS
LIST OF APPENDICES
1 INTRODUCTION
1.1
Background
1.2
Problem Statement
1.3
Objectives of Study
1.4
Significance of the Study
1.5
Scopes of Study
1.6
Organization of the Project Report
1
4
4
2
3
5
2 LITERATURE REVIEW
2.1
Introduction
2.2
Surface Grinding
2.2.1
Grinding Wheel
6
7
9
PAGE vi vii x xi ii iii iv v xvi xvii vii

2.3
Mechanics of Grinding
2.3.1
Spesific Heat Energy
2.3.2
2.3.3
Temperature During Grinding
Grinding Wheel Wear
2.3.4
Ductile Mode Machining of Hard and
Brittle Material
16
19
22
23
26
2.4
Metal Alloys: Structure and Heat Treatment
2.4.1
Introduction
2.4.2
2.4.3
Structures of Alloys
Phase Diagram
28
28
29
33
2.4.4
The Iron Carbon System
2.5
Heat Treatment of Ferrous Alloys
2.5.1
2.5.2
2.5.3
41
Time Temperature Transformation Diagram 45
Martensite
Continuous Cooling Transformation
38
47
Diagram
2.5.4
Tempered Martensite
2.6
Surface Roughness Measurement
50
53
57
2.6.1
2.6.2
Surface Structure and Integrity 57
Surface Texture and Surface Roughness 59
2.7
Rockwell and Superficial Hardness Test 60
3 RESEARCH METHODOLOGY
3.1
Component/Workpiece
3.2
Grinding Wheel
3.3
Grinding Process
3.4
Machine Tool
3.5
Measuring Equipments
3.6
Design of Experiment
3.7
Surface Roughness Measurement procedure
3.8
Superficial Hardness Test Procedure
62
62
63
63
66
67
70
70 viii

4 RESULT AND DISCUSSION
4.1
Result
4.1.1
4.1.2
Response 1 : Surface Roughness
Response 2 : Surface Hardness
71
73
79
4.2
Discussion
4.2.1
4.2.2
Surface Roughness
89
84
Surface Hardness / Superficial Hardness 85
5 CONCLUSION AND RECOMMENDATIONS
REFERRENCES
Appendices A1 - A10
91
93 - 117 ix

TABLE NO.
2.1
2.2
TITLE
Hardness value of abrasive material used in grinding wheel (I. D. Marinescu et. al., 2007)
PAGE
10
Marking system for conventional grinding wheels as defined by ANSI Standard (I. D. Marinescu et. al., 2007) 14
2.3
LIST OF TABLES
3.1
3.2
3.3
4.1
4.2
4.3
Approximation of the fraction of heat (R) going to the workpiece (S. Malkin, 1984)
Specifications of Grinding Machine
Experimental design table
Experimental design matrix
ANOVA for Response 2: Surface Hardness
The grinding operation parameters and the value of surface roughness and surface hardness obtain
ANOVA for Response 1: Surface Roughness
23
63
68
69
72
73
79 x

LIST OF FIGURES
TITLE FIGURE NO.
2.1 Schematic illustration of various surface grinding operation (a) Horizontal- spindle surface grinder: traverse grinding (b) Horizontal-spindle surface grinder: plunge
PAGE xi
8
2.2
2.3 grinding (S. Malkin, 1984)
Schematic illustration of a horizontal spindle surface grinder (S. Malkin, 1984)
Typical structure of grinding wheel
(I. D. Marinescu et. al., 2007)
8
13
2.4
2.5
2.6
Some of the standard wheel shape:
(I. D. Marinescu et. al., 2007)
A line diagram showing (a) the basic scheme of the surface grinding operation similar to that of the up milling operation and (b) the cutting action of active grain
15 that are randomly distributed in the periphery of bonded abrasive wheel .(V. C. Venkatesh et. al., 2006) 16
(a) Relationship between the cutting force and the wheel depth of cut in the three phases of grinding process
(b) specific energy decreases as the metal removal rate is increased throughout the three stages in the

2.7
2.8
2.9
2.10
2.11
2.12
2.13 grinding operation .(V. C. Venkatesh et. al., 2006)
A schematic of a horizontal surface grinding operation showing an individual undeformed chip and grinding parameters .(V. C. Venkatesh et. al., 2006)
17
18
Shows size effect relationship between chip thickness and resisting shear stress of a carbon steel modified by Taniguchi with the addition of tension test.
(V. C. Venkatesh et. al., 2006)
Radial volumetric wheel wear versus accumulated metal
21 removed for an external cylindrical grinding plunge grinding operation .(V. C. Venkatesh et. al., 2006) 24
A schematic illustration of the wheel wear mechanism :
(A) Attritious wear (B) Grain Fracture (C) bond fracture (D) Intrefacial grain bond fracture .
(V. C. Venkatesh et. al., 2006)
Conventional machining processes versus the
25 nanogrinding process
Cross section of gear teeth showing induction hardened surfaced (W. D. Calister, 2004)
27
28
(a) Schematic illustration of grain, grain boundaries, and particle dispersed throughout the structure of two phase system. (b) Schematic illustration of a two phase system consisting of two sets of grain: dark and light
(W. D. Calister, 2004) 33 xii

2.14
2.15
2.16
2.17
2.18
2.19
2.20
2.21
2.22
2.23
2.24
(a) Cooling curve for the solidification of pure metal.
Note that freezing take place at a constant temperature,
The latent heat of solidification is given off. (b) Change in density during the cooling of pure metal
(W. D. Calister, 2004)
Phase diagram for nickel copper alloy obtained at a slow rate of solidification . (W. D. Calister, 2004)
The lead-tin phase diagram. (W. D. Calister, 2004)
The iron –iron carbide phase diagram.
34
The unit cells for (a) austenite,
(b) ferrite, and (c) martensite 40
Microstructure of eutectoid steel. Spheroidite is formed by tempering the steel at 700
0
C. Magnification 1000X
(W. D. Calister, 2004) 42
36
37
39
(a) Hardness of martensite as a function of carbon content,
(b) Micrograph of martensite containing 0.8% carbon. 43
Hardness of tempered martensite as a function of tempering time for 1080 steel. (W. D. Calister, 2004) 45
(a) Austenite to pearlite transformation of iron carbon alloy as a function of time and temperature.
(b) Isothermal transformation diagram obtained from
(a) for a transformation temperature of 675
0
C.
(c) Microstructures obtained for a eutectoid iron carbon alloy as a function of cooling rate. (W. D. Calister, 2004) 46
Photomicrograph of a steel having a spheroidite microstructure. (W. D. Calister, 2004)
The body centered tetragonal unit cell for martensitic steel showing iron atoms (circles) and sites that may be
47 xiii

2.25
2.26
2.27
2.28
2.29
2.30
2.31
2.32
3.1
3.2
3.3
4.1
4.2 occupied by carbon atoms (crosses). For this tetragonal unit cell.(W. D. Calister, 2004)
The body centered hexagonal unit cell for martensitic steel
48 showing iron atoms (circles) and sites that may be occupied by carbon atoms (crosses). For this hexaonal unit cell (W. D.Calister, 2004)
Superimposition of isothermal and continuous cooling transformation diagram for eutectoid iron carbon alloy.
49
(W. D. Calister, 2004)
Moderately rapid and slow cooling curves superimposed
50 on a continuous cooling transformation diagram for a eutectoidiron – carbon alloy (W. D. Calister, 2004) 52
Continuous cooling transformation diagram for a eutectoid iron-carbon alloy and superimposed cooling curves
(W. D. Calister, 2004)
Electron micrograph of tempered martensite
52
(W. D. Calister, 2004)
Tensile and yield strength and ductility (%AR) versus
55 tempering temperature for an oil quenched alloy steel
(type 4340) (T. Tawakoli et. al., 2007)
The hardness of the alloy steel in tempering temperature
55
56 time (T. Tawakoli et. al., 2007)
Principles of the Rockwell and Rockwell superficial hardness tests (A. Nayar, 2005)
The grinding machine
Surface roughness tester machines
Hardness tester machine
Normal plot Residual (Surface Roughness)
Residual vs Predicted (Surface Roughness)
60
65
66
67
75
75 xiv

4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
Predicted vs Actual (Surface Roughness)
Interaction graph – cross feed and speed
(Surface Roughness)
76
76
Interaction graph- coolant and speed (Surface Roughness) 77
Interaction graph – speed and infeed (Surface Roughness) 77
Interaction graph – coolant and cross feed
(Surface Roughness) 78
Interaction graph – speed and infeed (Surface Roughness) 78
Normal plot residual (Surface Hardness) 81
Residual vs Predicted (Surface Hardness)
Predicted vs Actual (Surface Hardness)
Residual vs speed (Surface Hardness)
Interaction graph – Cross feed and speed
(Surface Hardness) 83
Interaction Graph – Infeed and speed (Surface Hardness) 83
81
82
82 xv

v d b
F
D t u
F t
F
H
F
V
V
P g
P b
P p
ANOVA pC
V w
V s
TTT
FCC
BCC
CCT
N h
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
LIST OF ABBREVIATIONS AND SYMBOLS
Proportion of abrasive grains in the total wheel volume
Proportion of bond material
Proportion of pores (air gaps)
Analysis of variance
Chip thickness
Specific grinding energy
Tangential grinding force
Horizontal grinding force
Vertical grinding force
Cutting speed
Workpiece speed
Infeed
Width of the cut
Wheel speed
Wheel diameter
Mean surface temperature
Volume specific heat
Volume remove
Volume of the wheel wear
Time-Temperature-Transformation
Face centered cubic
Body centered cubic
Continuous cooling transformation
Number specific to the Rockwell hardness scale
Permanent depth of indentation xvi

S
HB
HV
HPD
-
-
-
-
Scale unit, specific to the Rockwell hardness
Hardness Brinnel
Hardness Vickers
Depth of hardness xvii

APPENDIX
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
LIST OF APPENDICES
TITLE PAGE
Design Actual
Design Summary
Effect for Response 1: Surface Roughness
ANOVA for Response 1 : Surface Roughness
Diagnostic for Response 1: Surface Roughness 102
Model Graph for Interactions : Surface Roughness 105
93
94
95
96
Effect for Response 2: Surface Hardness
ANOVA for Response 2 : Surface Hardness
Diagnostic for Response 2: Surface Hardness
Model Graph for Surface Hardenss
108
109
113
116 xvii