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FIGURE 3. Surface texture and contour measuring instrument Variables that needed to be measured in truing and dressing process are shape and surface roughness. The shap« has to be controlled because the abrasive stick will be mounted in the blade of honing tool. However, in the case ot! this study and the practical use in the plant, only the surface roughness will be investigated. The roughness of abrasive sticks could affect the machined surface roughness (in this case, honed surface) [12]. Hence, in order to measure the roughness of the abrasive stick, the device used should be surface texture and contour measuring instrument (Figure 3). There are some roughness parameters definitions, including arithmetic average (Ra) roughness which is the most widely used in the engineering world. As another measuring instrument, the device complied to standards such as ISO, DIN, JIS, ASME, and others. For this study, JIS is used and to be specific JIS B0671.

Figure 3 Surface texture and contour measuring instrument Variables that needed to be measured in truing and dressing process are shape and surface roughness. The shap« has to be controlled because the abrasive stick will be mounted in the blade of honing tool. However, in the case ot! this study and the practical use in the plant, only the surface roughness will be investigated. The roughness of abrasive sticks could affect the machined surface roughness (in this case, honed surface) [12]. Hence, in order to measure the roughness of the abrasive stick, the device used should be surface texture and contour measuring instrument (Figure 3). There are some roughness parameters definitions, including arithmetic average (Ra) roughness which is the most widely used in the engineering world. As another measuring instrument, the device complied to standards such as ISO, DIN, JIS, ASME, and others. For this study, JIS is used and to be specific JIS B0671.

Related Figures (12)

FIGURE 1. Honing tool truing and dressing process with (a) disassembly of honing and (b) truing of honing tool
FIGURE 1. Honing tool truing and dressing process with (a) disassembly of honing and (b) truing of honing tool
Cutting parameters in truing and dressing process using a cylindrical grinding machine are several including wheel speed and spindle speed (fixed into respectively 1250 rpm and 50 rpm) but only two used as the variables which are the depth of cut and feed rate. These two parameters then combined in the experiment. Feed rate started from 110 mm/min to 200 mm/min, and the depth of cut started from 3 jum to 25 um. The feed rate divided into 10 (increasing every 10) and depth of cut divided into 4. So, there would be 40 combinations of parameters as can be seen in Table 1. The process is using soluble oil as cutting fluid. Honing stone (known as the abrasive stick in the market) that would be trued and dressed is a metal-bonded diamond with 500 grit size (fine). The dresser tool for honing stone is green vitrified bonded silicon carbide with 600 grit size (fine). Truing and dressing as one kind of subtractive manufacturing have the main characteristic that the cutting tool has to be higher in quality (in this case, the grit size). It could be seen in Figure 2.
Cutting parameters in truing and dressing process using a cylindrical grinding machine are several including wheel speed and spindle speed (fixed into respectively 1250 rpm and 50 rpm) but only two used as the variables which are the depth of cut and feed rate. These two parameters then combined in the experiment. Feed rate started from 110 mm/min to 200 mm/min, and the depth of cut started from 3 jum to 25 um. The feed rate divided into 10 (increasing every 10) and depth of cut divided into 4. So, there would be 40 combinations of parameters as can be seen in Table 1. The process is using soluble oil as cutting fluid. Honing stone (known as the abrasive stick in the market) that would be trued and dressed is a metal-bonded diamond with 500 grit size (fine). The dresser tool for honing stone is green vitrified bonded silicon carbide with 600 grit size (fine). Truing and dressing as one kind of subtractive manufacturing have the main characteristic that the cutting tool has to be higher in quality (in this case, the grit size). It could be seen in Figure 2.
FIGURE 6. Calibration condition 3. Set the condition of calibration (parameter and reference value) and execute.
FIGURE 6. Calibration condition 3. Set the condition of calibration (parameter and reference value) and execute.
FIGURE 7. Calibration result Calibration result is generated.
FIGURE 7. Calibration result Calibration result is generated.
Table 2 recounts the relationship between the depth of cut-feeding rate and arithmetic surface roughness. From the table, it could be concluded that increasing depth of cut, the surface roughness of honing tool coarser. The range of roughness, seen in column 3, varied from 1,192 um to 2,316 um. Interestingly, there is a value that intersected at every depth of cut value to next like when depth of cut 3 um roughness is varied from 1,192 to 1,733 while at 5 um from 1,501 to 1,926 um. The trend is continued in that manner. RESULTS
Table 2 recounts the relationship between the depth of cut-feeding rate and arithmetic surface roughness. From the table, it could be concluded that increasing depth of cut, the surface roughness of honing tool coarser. The range of roughness, seen in column 3, varied from 1,192 um to 2,316 um. Interestingly, there is a value that intersected at every depth of cut value to next like when depth of cut 3 um roughness is varied from 1,192 to 1,733 while at 5 um from 1,501 to 1,926 um. The trend is continued in that manner. RESULTS
The first test is t-test and started by determining the t value as from t distribution table. With dF (degree of freedom) equal to 37 for 40 samples and minimum probability 0.025, t value is 2.02619. By using statistic software, t value for feeding and depth of cut is independently generating value higher than t from distribution value (Table 3). So, in conclusion, the feeding and the depth of cut affecting the surface roughness.
The first test is t-test and started by determining the t value as from t distribution table. With dF (degree of freedom) equal to 37 for 40 samples and minimum probability 0.025, t value is 2.02619. By using statistic software, t value for feeding and depth of cut is independently generating value higher than t from distribution value (Table 3). So, in conclusion, the feeding and the depth of cut affecting the surface roughness.
FIGURE 8. Surface roughness test
FIGURE 8. Surface roughness test
The last test is used to determine the percentage of affecting. It is 87.2 % from the R square value. Confirmed by the first test, the second test (F-test) determine whether the two variables are affecting the roughness simultaneously. F value from dF of N1 equal to 2 and N2 equal to 38 for 40 samples is 3.24. F value for feeding and depth of cut simultaneously generating value higher than F from distribution value (Table 4). So, in conclusion, feeding and the depth of cut affecting the roughness simultaneously.
The last test is used to determine the percentage of affecting. It is 87.2 % from the R square value. Confirmed by the first test, the second test (F-test) determine whether the two variables are affecting the roughness simultaneously. F value from dF of N1 equal to 2 and N2 equal to 38 for 40 samples is 3.24. F value for feeding and depth of cut simultaneously generating value higher than F from distribution value (Table 4). So, in conclusion, feeding and the depth of cut affecting the roughness simultaneously.
CONCLUSION
CONCLUSION
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