Effect of Dressing Parameters on Material Removal Rate when Surface Grinding SKD11 Tool Steel

Abstract

Nowadays, surface grinding is one of the most common of metal finishing methods. The efficiency of this process is affected by the so-called process parameters such as dressing feed rate (S), rough dressing depth (ar), rough dressing times (nr), fine dressing depth (af), fine dressing times (nf), and non-feeding dressing (nnon). etc. In this paper, the optimization of dressing parameters in surface grinding SKD11 tool steel is studied. The aim of the study is to find the most appropriate value set of dressing parameters to maximize the material removal rate (MRR). In order to solve the problem, the Taguchi method is used. Based on an orthogonal array L16(44x22), sixteen experiments have been conducted. By analyzing the experimental results, an optimal solution of such optimization problem has been solved, presenting the most appropriate dressing parameters as follows: ar = 0.015 mm, nr = 2 times, af = 0.005 mm, nf = 0 times, nnon = 0 times, S = 1.6 m/min. The discovered technology mode has been applied to the real machining process and the outcome shows out a much better result in comparison with default setting modes, that the difference between the model values and the real values of the roughness average is controlled within 3.87% of the ranges.