Title: Experimental studies to validate simulated results for nozzle effectiveness using multi-response optimisation during cylindrical grinding process

Authors: Anirban Bhattacharya; Ajay Batish; Mandeep Singh

Addresses: Mechanical Engineering Department, Thapar University, Patiala – 147004, India. ' Mechanical Engineering Department, Thapar University, Patiala – 147004, India. ' Mechanical Engineering Department, Thapar University, Patiala – 147004, India

Abstract: The computational fluid simulation (using ANSYS CFX module) approach was used to study six different nozzle shapes and cross section to study the grinding fluid flow behaviour through them. On the basis of the simulation study, two best shapes of nozzles namely spline followed by convergent-divergent were identified for obtaining the peak velocity of the fluid. The results were experimentally validated using all the six nozzles used in the simulation study along with other grinding process parameters to identify the parameters which significantly affect the quality of the grinding output. The results showed different level settings for the three factors for optimising the three response parameters. Multi-response signal-to-noise (MRSN) was used to optimise the three responses together. Spline shaped nozzle gave the best results for the three responses followed by convergent divergent which also validated the simulation study results. The workpiece speed and nozzle tip distance were key factors that affect the surface roughness, dimensional stability and the microhardness of the machined parts. Further, wheel speed and nozzle inclination angle do not affect any of the responses.

Keywords: cylindrical grinding; nozzle effectiveness; computational fluid dynamics; CFD; simulation; surface roughness; dimensional control; microhardness; multi-response optimisation; surface quality; fluid flow behaviour; nozzle shapes.

DOI: 10.1504/IJMATEI.2012.049261

International Journal of Materials Engineering Innovation, 2012 Vol.3 No.3/4, pp.165 - 189

Published online: 28 Sep 2012 *

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