Modification of Existing Machine For Data Automation of Belt Testing Machine

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
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
Abstract: In the manufacturing sector, surface imposes less strain on the work piece when compared
to other forms of grinding; cracking, burning etc.
grinding testing machine plays important role.
Grinding in this machine parameters to be considered In order to evaluate and optimize product
are surface quality and metal removal rate. Several performance, we must focus on the interaction of the
factors which include depth of cut, wheel grade, wheel grinding product with the entire grinding process. A
speed, material properties and table speed affects the grinding process is much more difficult to control and
machining In belt testing machine we find life of the optimize than other machining processes such as
belt. Also different parameters of belt like cycle turning or milling because in grinding there are
timing, power, MRR. During this process of belt literally thousands of miniature cutting tools acting on
testing machine, we find material removal to calculate the work piece in a more or less random manner.
material removal rate, by using manually weighing There are also more process variables in grinding than
method, so to automate material removal rate we in most other machining processes, with perhaps a
proceed with different method. One of our methods is dozen significant variables related to the performance
length reduction method. This method can be achieved of the grinding product alone.
by distance measuring devices.
Keywords: Grinding testing machine, MRR, Grinding has traditionally been used for metallic
power, cycle time 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
1. INTRODUCTION also be the fabrication process of choice for several
Belt grinding machines achieve rates of high newer and lesser-known classes of materials such as
production efficiency, quality finish and economy carbon and metallic foams, bulk amorphous metals
never realized in any other method of grinding or (metallic glasses), ceramic-magnets, intermetallic, and
polishing. For example, by changing grit sizes, a composite materials. Anyone faced with grinding
machine may be converted from a heavy duty grinder these materials should be interested in a cost-effective
to a fine micro polisher. Belt grinding machines can be grinding process while maintaining required
adopted for semi-automatic or fully automatic dimensional tolerances, surface characteristics, and
working. Further, in most applications, belt grinding mechanical properties.
IDL - International Digital Library 1|P a g e Copyright@IDL-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
Fig 1.1: Belt Testing Machine
certain unit of material from the steel. Its units are W
min/in3.(1)
1.4EXISTING SYSTEM
1.4.1 DATA COLLECTION IN BELT TESTING

MACHINE
Initial belt weight

Final belt weight
Initial job weight
Fig1.2: Belts used in Testing Machine Final job weight
Cycle time
Power drawn
1.3 NOMENCLATURE
Force (F)
1.3.1 MRR-Material removal rate. This is
1.4.2 PRESENT SITUATION FOR DATA
the normalized rate at which material is removed from
COLLECTION
the steel during grinding. For our calculations, MRR
was normalized so the width of grinding wheel does 1. AUTOMATED DATA
not have an effect on the MRR used for our
calculations. Its units are in 3/min/in. The Cycle time- The cycle time is collected in fis file.
This fis file is hooked up to spm machine. Fis file is
1.3.2 BWR- Belt wear rate. This is the collects automated data and transfers in to the excel
normalized rateat which material is removed from the sheet. This cycle time is automated.
grinding wheel during grinding. For our calculations, Power- The power (idle) is also collected in fis file.
BWR was normalized so the width of grinding wheel This fis file is hooked up to spm machine. The
does not have an effect on the BWR used for our geometric power is recorded in fis file.
calculations. Its units are in 3/min/in.
2. NON AUTOMATED DATA
1.3.3 UNIT POWER-It is the normalized
amount of power that is required to spin the grinding
Material removal (MR)-The material removal can
wheel during the grinding process. Its units are W/in.
determine by taking the difference between the initial

weight and final weight of job. The MR is non- The samples have to joint to 2000mm or
automated 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.
1.5 METHOD OF TESTING BELT Take all the 50 flats (SS304 or CRV), weigh
PERFORMANCE IN MACHINE them separately and record the wights in the
format saved in the computer.
1 OBJECTIVE: Weigh the belt and note down its weight in
To assess the coated abrasive cloth belt product for its the format saved in the computer .
performance against a standard/New product coated Mount the belt on to the tester. Align the belt
abrasive cloth belt product. in running condition using the tracking
arrangement provided in the tester.
2 SCOPES:
These instructions are applicable to
products as indicated in the DOC #QAD/CH/01. 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
2. OBJECTIVES
to be tested for performance test,
To automate the material removal rate.

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 3.2 EXPERIMENTAL WORK

most material removal processes is keeping accuracy
LVDT Working principle
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 Fig 3.1 LVDT
Weight reduction method
Volume reduction method
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

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 Fig 3.3 finding the reduction length by LVDT
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)
3.3 PLACING OF LVDT
Fig: 3.4 layout of belt testing machine

Fig 3.6 Positioning of LVDT
3.4LVDT specification
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
Fig 3.5 3D model LVDT setup Operating Temperature: 100 to 60C (4)
3.5 PROCEDURE
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.

When the machine is started work piece 5 9.0 22.5 1080 8.44 0.936
carriage will move towards grind wheel at the 6 8.9 21.4 1027.2 8.01 0.902
same time correspondingly LVDT also move.
7 8.8 20 960 7.5 0.85
When the work piece plunges to grind wheel
at the same time LVDT needle will plunge to 8 8.9 18 864 6.74 0.757
obstacle. 9 8.9 16.86 809.28 6.31 0.709
The decreases in the work piece length is
10 9.0 16 768 6 0.665
noted in the digital indicator of LVDT
The value of displacement in the digital 6
indicator (RS-232) is transferred to the fis file
in the computer.
Material specification:
Material = Chromium vanadium steel

Density=7.8*10 kg/mm3
-3
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 Cy Differ Volume= MR= MRR

cle
cle ence width*thick density*v =
no
tim length *length olume MR/t
3
e (mm) (mm ) (gm) ime
(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

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
Fig 3.8SGE v/s cum.MR
efficiency of the abrasive belt.
When we conducted test we got some results that are
4. IMPLEMENTATION Table 6.1 Comparison between manual v/s

automated MRR
This is implemented in grinding testing
machine Sl no. MRR (Manual MRR(Automated
LVDt is added to machine calculation) calculation)
It can be implemented in others machines 1 1.378 1.378
where the length is a factor to find out.
A similar investigation can be taken up with 2 1.200 1.2
much more emphasis on the sensors aspects
3 1.089 1.073
making it more feasible and requiring in
depth measuring properties. 4 1.056 1.0306
The machine is processed with change in
length basis for the present; investigation 5 0.956 0.936
could be made through alternate processing From above table the results we got are
routes such as mass reduction, robotic parts.
Belt wear test may be conducted with accepted.
further variations of parameters such as
force applied, pressure, heat produced. REFERENCES
1) Determining material properties Responsible for
Grinding performance
5. OUTCOMES
(Benjamin Hall, Jonathan king, Justin
The theoretical values and practice values are Prange)
matching
2) http://www.google.com/patents/US4149409
It increases efficiency by reducing time
During the process it reduces human errors 3)www.saint-gobain.co.in/
by automating data

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
(StphaneAgnarda, 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*)

Modification of Existing Machine For Data Automation of Belt Testing Machine

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Modification of Existing Machine For Data Automation of Belt Testing Machine

Загружено:

Авторское право:

Доступные форматы

IDL - International Digital Library Of

Technology & Research

International e-Journal For Technology And Research-2017