CHAPTER 4

RESULTS AND ANALYSIS

4.1 INTRODUCTION

This chapter will discuss further about this project which is focusing on the
result and analysis that had obtained. In order to obtain the results, the methodologies
were taken as the main consideration to take care of. The analysis had been done which
the results need to be comparing both experimental and theory. The entire data and
figures obtained are represented in this chapter in details.

4.2 EXPERIMENTAL RESULTS

4.2.1 Surface Roughness

The 36 experiments were runs and had been conducted in mechanical laboratory
with the different number of passes. The observations of the microstructure at the
surface in Haynes 242 after grinding with both wheels SiC and Al2O3 were analyzed by
using 2D-metallurgical microscope. Apart from that, the experimental result of the
surface roughness was done by using S2 perthometer in order to obtain the reading of
Ra. The whole result then were taken, calculated and tabled. Final analysis of this
project was analyzed by using Neural Network analysis. Figure below shows the
analysis of the surface roughness, Ra by using Neural Network analysis and 2D-
microstructure by using metallurgical microscope.
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4.2.2 The 2D-microstructure of Haynes 242

Multi pass
Surface Roughness (µm)
Single pass

5 13 21
Depth of cut (µm)

Figure 4.1: 2D- microstructure of Haynes 242 when grinds with SiC wheel by using
metallurgical microscope
Multi pass
SurfaceRoughness (µm)
Single pass

5 13 21
Depth of cut (µm)

Figure 4.2: 2D- microstructure of Haynes 242 when grinds with Al2O3wheel by using
metallurgical microscope
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Figures 4.1 and 4.2 shown the 2D- microstructure of Haynes 242 when grind
with the two different wheel. The figure 4.1 was the microstructure of Haynes 242 when
grind with the SiC wheel. The microstructure of the surface roughness shown in the
multi-pass grinding process are more smooth compare to the microstructure of the
surface roughness in the single-pass grinding processes. The single-pass process gives
the surface roughness rougher where it can be seen the grit silver line produced by the
wheel. The lines appear as the replicates of the grit wheel and there is a several small
damage towards the surface. This is may be due to the applied force by the wheel during
the grinding processes. The microstructure of the surface roughness in the multi-pass
grinding process are much better and smoother where the small of width lines occur,
figure 4.2. The small damage also occur once the workpiece was grind with first number
of passes but then was removed by the next passes.The surface was observed anf found
out that the surface was cleaned by small damage since the process consist numbers of
pass, passing repeatedly until the desired cylces reached. These had showed an
agreement that a two stage of grinding process is recommended (multi-pass) which led
to reduced cycle time without deterioration in the surface finish where optimization the
grinding process (A.P Walsh, 2002). From the both figure which had been grind with
the two different wheel, the Al2O3 wheel was gave the best microstructure of surface
roughness. This is due to the high hardness of the wheel compare to the SiC wheel. The
wheel are tends to be more tough during cutting action where the sparkling produced
during the process which means the high friction force occur at the surface contact
between the wheel and the workpiece. The coolant was used to reduces the excessive
heat toward the workpieces
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4.2.3 Analysis of the surface roughness, Ra by using Artificial Neural Network

Surface Roughness

1.5
Surface Roughness (µm)

1.0

0.5

5 10 15 20
Depth of cut (µm)

Figure 4.3: Relationship between Surface Roughness versus Depth of cut for single-
pass by using SiC grinding wheel
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Surface Roughness
0.35
Surface Roughness (µm)

0.30

0.25

0.20
5 10 15 20
Depth of cut (µm)

Figure 4.4: Relationship between Surface Roughness versus Depth of cut for multi-pass
by using SiC grinding wheel

Figures 4.3 and 4.4 above had shown the results of the experiment that had been
done in the grinding laboratory by using the SiC grinding wheel. The figure 4.3 shows
the results where the experiment was run with the single-pass stage where the wheel
was passing through only one pass on the surface workpiece. The lowest value of the
surface roughness that was obtained was 0.35µm at the depth of cut 5µm.While that, the
figure 4.4 shows the results where the experiment was run with the multi-pass stage
where 2 cycles of grinding processes was done. The lowest value of the surface
roughness that was obtained in the multi pass grinding processes was 0.216µm at the
lowest depth of cut were used which 5µm.
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Surface Roughness
0.4

Surface Roughness (µm)

0.3

0.2

0.1
5 10 15 20
Depth of cut (µm)

Figure 4.5: Relationship between Surface Roughness versus Depth of cut for single-
pass by using Al2O3 grinding wheel
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Surface Roughness

0.24
Surface Roughness (µm)

0.22

0.20

0.18

0.16
5 10 15 20
Depth of cut (µm)

Figure 4.6: Relationship between Surface Roughness versus Depth of cut for multi-pass
by using Al2O3 grinding wheel

Figures 4.5 and 4.6 above had shown the results of the experiment that had been
done in the grinding laboratory by using the Al2O3 grinding wheel. The same pattern of
both figure were obtained although it was using with the different number of passes in
the grinding processes. The experiment which shows the results in figure 4.5 was using
the single-pass grinding process. From the graph in the figure 4.5, the lowest value of
surface roughness was 0.151µm where the lowest value of the depth of cut was used
which is 5µm. Apart from that, the lowest value of the surface roughness in the multi-
pass grinding process, figure 4.6 was 0.167µm.
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4.3 COMPARISON RESULTS AND ANALYSIS

4.3.1 Comparison results between Silicon Carbide and Aluminium Oxide

Silicon Carbide
Aluminium Oxide

1.5
Surface Rouhgness (µm)

1.0

0.5

0.0
5 10 15 20
Depth of cut (µm)

Figure 4.7: Comparison of Depth of cut versus Surface Roughness by using different
wheel for-single pass grinding process

Figure 4.7 shows the comparison of depth of cut between surface roughness of
the Haynes 242 by using two different wheel which are SiC and Al2O3 wheel. Both
experimental that had done were using single-pass of grinding processes. The both
graph shown that increasing the depth of cut, slightly increases the value of surface
roughness. This result is consistent with experimental findings by Habeeb, H. al. (2010)
where increase in the depth of cut, surface roughness becomes rougher. By using the
Al2O3 wheel, the value of the surface roughness increased consistently where the
differences of the value were in control. However, it is clearly shown that the Al2O3
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wheel gives a lowest value of surface roughness, Ra, rather than SiC wheel. The lowest
value of Ra that was using Al2O3 wheel was 0.151µm while the SiC wheel gives
0.35µm at the depth of cut of 5µm. Thus, the value 0.35µm indicates that surface
roughness of Haynes 242 by using SiC wheel is rougher compare to the Al2O3 wheel.
This is shows the cutting action by the grinding wheel gives a great impact towards the
surface roughness. Since the processes were in the single-pass stage, the wheel only
passes through 1 time only on the flat surface of the workpieces. During the grinding
processes, the power transmitted and generates friction. The excessive power and
friction might cause the workpiece damage that gives the wokpices high temperatures
and thus prevents the fine suface finish and desirable accuracy. To reduce the
temperature during the process, the coolant which water based coolant was used during
the experiment and gives the good of surface roughness as the results.

Silicon Carbide
0.35 Aluminium Oxide
Surface roughness (µm)

0.30

0.25

0.20

5 10 15 20
Depth of cut

Figure 4.8: Comparison of Depth of cut versus Surface Roughness by using different
wheel for multi-pass grinding process
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Figure 4.8 shows the comparison of depth of cut versus surface roughness by
using two different wheels but with the multiple-pass of grinding process. The
experiment that had done was gives the results and was graph. The same pattern of the
graph obtained with the single-pass grinding process. The figure above shows the
relationship of independent variable was directly proportional to the dependant variable.
On the other words, increasing the depth of cut from 5µm to 21µm slightly increases the
surface roughness of the workpiece. For the surface roughness that had grind with the
SiC wheel, increased from the value 0.216µm to 0.337µm. The same goes to the Al2O3
wheel where the value was increased from 0.167µm to 0.243µm. This may be due to the
formation of chips that may charge at the surface of the grinding wheel during the
grinding process. The chip that sticks at the wheel cause poor performance of the
cutting action and the wheel become dull. Thus, it effects the cutting action by the
wheel and gives the poor condition of the surface roughness.

Silicon Carbide
Aluminium Oxide

0.015
wheel wear (mm)

0.010

5 10 15 20
Depth of cut (µm)

Figure 4.9: Comparison of Depth of cut versus wheel wear by using different wheel for
single-pass
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Figures 4.9 above had shown the relationship between depth of cut and the
wheel wear for single-pass grinding processes. From the figure above, the graph of
wheel wear was increased with increasing the depth of cut. The black line indicates the
SiC wheel and the red line indicates the Al2O3 wheel. Both regression lines was slightly
increased which mean the wheel wear occur during the processes. When the large
values of depth of cut were used, the large ratios were obtained. This can be seen in the
graph where the maximum value of depth of cut was used which is, 21µm, gives the
highest wheel wear for both wheels which are 0.015mm when using the SiC wheel and
0.017mm of wheel wear produces when using the Al2O3 wheel. However, the value of
wheel wear when using Al2O3 compare to the SiC wheel. This may be due to the size of
grit of the wheel and hardness of the Al2O3 wheel which are better and hardened
compare to the other one. The phenomenon of wheel wear occur during the grinding
process was observed by measuring the diameter of the wheel before and after the wheel
that had been used. The observation had been done and measured, when realizing the
diameter of the wheel had been decreased. This is because of the cutting feed of
between the surface of the wheel and workpieces.

Silicon Carbide
0.032 Aluminium Oxide

0.030
wheel wear (mm)

0.028

0.026

0.024
5 10 15 20
Depth of cut (µm)

Figure 4.10: Comparison of Depth of cut versus wheel wear by using different wheel
for multi-pass
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Figure 4.10 above had shown the relationship between depth of cut and the
wheel wear for multi-pass grinding processes. The same pattern of the graph was
obtained where increasing the depth of cut, increases the wheel wear produced. Since
the multi-pass processes were used, the value of wheel wear becomes two times higher
from the single-pass process. The maximum value of the depth of cut were used which
is 21µm, produced 0.03mm wheel wear for SiC wheel and 0.031mm for Al2O3 wheel.
The value obtained was doubled from the single-pass process due to the number of
cycle that has been used. The two cycle of the grinding process were used this times
which is equal to the four numbers of passes through to the surface contact between
wheel and the workpiece and had caused the wheel wear produced becomes higher.
Moreover, grinding wheel wear unevenly under most general grinding operations
because of uneven pressure applied to the face of the wheel when it cuts. For certain
operations, the wheel may become dull before it is broken loose from the wheel bond.
In these cases, it is necessary that the wheel to be dressed to restore its efficiency and
accuracy. This is supported by P. Krajnik, 2005 which is said grinding wheel dressing
condition most significantly affects the ground surface roughness. Dressing operations
was done while handling this experiments where the cutting action towards the face of a
grinding wheel. It is to restore its original cutting qualities. The operations are
performed with a tool called abrasive diamond dresser. This operations also might cause
the diameter of the wheel become decreased where lead to the wheel wear produced.
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4.3.2 Comparison analysis between Calculation Value and ANN

Table 4.1 : Calculation based on theory of Multi-pass Aluminium Oxide wheel

x y xy X2 Y2

5 0.167 0.835 25 0.028

7 0.178 1.246 49 0.032
9 0.192 1.728 81 0.037
11 0.196 2.156 121 0.038
13 0.202 3.000 169 0.041
15 0.225 3.375 225 0.051
17 0.236 4.012 289 0.056
19 0.240 4.56 361 0.058
21 0.243 5.103 441 0.060
∑x = 117 ∑y = 1.879 ∑xy = 26.015 ∑x2 = 1761 ∑y2 = 0.401
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Table 4.2: Summary of Neural network analysis and calculation value for surface
roughness

Surface Roughness
Abrasive Number of Correlation R-Squared
Material passes Neural Calculation Neural Calculation
Network Network
Silicon Single-pass 0.99852 0.8482 0.996518 0.7194
Carbide Multi-pass 0.997193 0.9727 0.991149 0.9461
Aluminium Single-pass 0.993659 0.9564 0.984287 0.9147
Oxide Multi-pass 0.999619 1.00 0.999112 1

The table 4.1 above was the theory calculation for multi-pass grinding process
by using Al2O3 wheel. The calculation was done in order to obtain the correlation value
which is r and the coefficeint of determination which is R2 value. The correlation value
were used is to measures the degree of association which the values range from -1 to +1.
If there is a strong positive linear relationship between the variables, r will be close to
+1. Since the final value of the calculation above was equal to the 1, so , there is a
strong positive linear relationship between the variable the depth of cut and surface
roughness. The r was calculated theoritically in order to compare it with the r that were
obtained by using Neural network analysis.

The table 4.2 is the summarization of the both r and R2 value which had done
calculated using theoritical formulae and from the neural betwork analysis. The
comparison of the analysis had been done and there is less different both analysis
theoritically and by using neural network analysis. The multi-pass grinding process
using Al2O3 give the best of r which is equal to the 1 by theoritically and 0.999619 by
using neural network analysis. The value was in acceptable range and it can be seen that
the r was affected by the depth of cut. This mean there is a strong relationship and less
or error occur between the variables. The regression coefficients obtained from testing
of the ANN were perfect and within the acceptable limits in both cases. As the
correlation coefficient approaches to 1, the accuracy of the prediction improves. Since
there is less different of r in both analysis, the prediction value was been built in order
to see the further value of the surface roughness with the less error by increases the
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value of depth of cut. According to the Kurt, H. and Kayfeci, M. 2009 as the correlation
coefficients range is very close to 1, it indicates excellent agreement between the
experimental and the ANN predicted results.

4.3.3 Comparison prediction results by ANN

Single pass
Multi pass

perdiction value
1.5
Surface roughness (µm)

1.0

0.5

0.0
0 10 20 30
depth of cut (µm)

Figure 4.11: Prediction increasing the value of depth of cut versus Surface
Roughness by using SiC wheel
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single pass
0.4 multipass
prediction range
Surface roughness (µm)

0.3

0.2

0.1
0 10 20 30
depth f cut (µm)

Figure 4.12: Prediction increasing the value of depth of cut versus Surface
Roughness by using Al2O3 wheel

Figure 4.11 and 4.12 above had shown the graph of the prediction in increasing
the value of depth cut versus Surface Roughness. The figure 4.11 shown which is the
prediction graph was using by SiC wheel. The prediction was done by using the initial
prediction value of the depth cut which 22µm with increment 1µm until 30µm which
had been built with the dotted green line. The graph had shown after the 21µm value of
the depth of cut, the value of surface roughness increased and become constant. The
value of the surface roughness in the single-pass process increased to 1.45µm while the
value of surface roughness in the-multi pass process increased to 1.44µm and finally
both graph becomes constant. The same phenomenon goes to the prediction graph when
using the Al2O3 wheel. Figure 4.12 was also shown an increasing the depth of cut,
increased the surface roughness. The initial prediction values also begin with 22µm with
increment 1µm until 30µm. The graph that was using Al2O3 wheel in the single-pass
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process was increased with the value of surface roughness up to 0.35µm while in multi-
pass process the surface roughness was increased up to 0.23µm at the depth of cut
23µm. It was proven that multi-pass process by using the Al2O3 give the lowest value of
the surface roughness which indicates that it has the smooth of surface finish. The value
of surface roughness becomes was not increased anymore after the depth of cut 23µm
and the graph becomes constant. Within this range, the surface roughness was said it
reach the optimize stage and also the optimization stage of the grinding process and if
the process was done in the lab, it cannot reach the higher stage anymore.