Identification of Vibration Signature for Grinding Process
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Department of Mechanical and Production Engineering(MPE), Islamic University of Technology(IUT), Board Bazar, Gazipur-1704, Bangladesh
Abstract
Grinding is one of the most important finishing operations in modern manufacturing. Despite
its widespread use, the grinding process faces several challenges, including vibrations, chatter,
thermal damage, and grinding wheel wear, all of which can reduce productivity. This thesis
investigates the identification and analysis of vibration signatures in the grinding process to
develop a framework for real-time condition monitoring. Experimental studies were conducted
to evaluate the effects of Magnetic Field-Assisted Grinding (MFAG) and Ultrasonic Vibration
Assisted Grinding (UVAG) on surface roughness in cylindrical grinding of mild steel. The
experiments involved a structured sequence of operations: conventional grinding to establish a
baseline, followed by MFAG and UVAG under varying process parameters. In MFAG, a static
magnetic field was applied at different distances from the workpiece. Results demonstrated a
complex interaction, where the magnetic field reduced surface finish by 35.38% under specific
conditions (3 mm magnet distance) compared to conventional grinding (33.7%), but also
revealed 2 mm magnet distance at low depth of cut showing better surface finish. In UVAG,
the application of ultrasonic vibrations proved highly effective but distinctly frequency
specific. A frequency of 40 kHz yielded the most significant improvement, achieving a 35.54%
reduction in surface roughness. A quadratic mathematical model for the UVAG process was
developed by utilizing a Central Composite Design (CCD) and Analysis of Variance
(ANOVA). The model identified workpiece rotational speed (RPM) as the most influential
parameter affecting surface roughness. Subsequent optimization through desirability function
analysis determined the ideal parameter combination for minimizing surface roughness to be
an ultrasonic frequency of 31.8 kHz, a depth of cut of 0.092, and a workpiece RPM of 336,
predicting an optimal surface roughness (Ra) of 2.88 µm. The study concludes that vibration
signature analysis, combined with advanced assistance techniques, offers a viable pathway for
real-time grinding process monitoring and control, contributing to enhanced manufacturing
precision and efficiency.
Description
Supervised by
Prof. Dr. Md Anayet Ullah Patwari,
Department of Mechanical and Production Engineering(MPE),
Islamic University of Technology (IUT)
Board Bazar, Gazipur-1704, Bangladesh.
This thesis is submitted in partial fulfillment of the requirements for the degree of Bachelor of Mechanical and Production Engineering, 2025
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Citation
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