IJE TRANSACTIONS C: Aspects Vol. 29, No. 12 (December 2016) 1775-1782    Article in Press

downloaded Downloaded: 93   viewed Viewed: 1828

V. Alimirzaloo, V. Modanloo and E. Babazadeh Asbagh
( Received: August 13, 2016 – Accepted in Revised Form: November 11, 2016 )

Abstract    One of the challenges in the printing industry is the presence of extra lines in printing design. This problem is due to the improper surface roughness of carved cylinders. This research endeavors to specify and optimize the effective parameters on the surface roughness of chrome coated printing cylinders in the finishing process that is done using a finish star machine. Investigated parameters include lubricant volume, feed rate of machine head, emery feed rate, emery compressive force, emery vibration and peripheral speed. By performing some experiments designed by response surface methodology, suitable ranges for the parameters were determined using contour plots and desirability function approach. Results show that the head feed rate, peripheral speed of the part and emery force are the significant parameters on the surface roughness. Surface roughness decreases by reducing the head feed rate. By increasing the emery force up to ten kilogram, surface roughness increases but afterwards gradually decreases. The roughness decreases by increasing the peripheral speed of the part up to 40 m/min, but increases after this value. At last, suitable range and optimal value of the effective process parameters was achived for the desirable surface roughness that is between 0.32 to 0.37 micron.


Keywords    Printing Cylinders, Roughness, Finishing, Response Surface Methodology


چکیده    یکی از مشکلات موجود در صنعت چاپ با سیلندر چاپ حکاکی شده، وجود خطوط اضافه در چاپ یا کم‌رنگ و پررنگ بودن طرح چاپی می‌باشد که این مشکل عمدتا ناشی از زبری سطح نامناسب سطح سیلندر چاپ می‌باشد. در این پژوهش تلاش شده است تا عوامل تاثیرگذار بر زبری سطح سیلندرهای چاپ با پوشش کروم در فرآیند پرداختکاری با استفاده از دستگاه فینیش استار شناسایی و بهینهسازی شود. پارامترهای مورد مطالعه شامل مقدار روانکار، میزان پیشروی هد دستگاه، میزان پیشروی سنباده، نیروی فشاری سنباده، میزان ارتعاش سنباده و سرعت محیطی قطعه‌‍‌کار چاپ میباشد. با انجام تجربی آزمایشهای طراحی شده با روش رویه پاسخ، محدوده مناسب پارامترها برای زبری مطلوب با استفاده از نمودارهای کانتوری و روش تابع مطلوبیت بدست آمد. نتایج نشان میدهد که پارامترهای سرعت پیشروی هد، سرعت محیطی و نیروی سنباده سه عامل تاثیرگذار میباشند. با کاهش میزان پیشروی، زبری سطح کاهش می‌یابد. با افزایش نیروی سنباده تا ده کیلوگرم زبری سطح افزایش ولی با تجاوز از ده کیلوگرم زبری سطح به تدریج کاهش می‌یابد. همچنین با افزایش سرعت محیطی تا چهل متر بر دقیقه، زبری سطح کاهش می‌یابد ولی بعد از آن افزایش می‌یابد. محدوده مناسب و مقدار بهینه پارامترهای مؤثر، برای زبری سطح مطلوب که بین 32/0 تا 37/0 میکرون است استخراج شد.


1.      Kumar, N., "Optimization of cylindrical grinding process parameters on c40e steel using taguchi technique", International Journal of engineering Research and Applications,  Vol. 1, No. 5, 100-104.

2.      Kiyaka, M., Cakirb, O. and Altana, E., "A study on surface roughness in external cylindrical grinding", in 12th International Scientific Conference Achievements in Mechanical & Materials Engineering., (2003).

3.      Demir, H., Gullu, A., Ciftci, I. and Seker, U., "An investigation into the influences of grain size and grinding parameters on surface roughness and grinding forces when grinding", Strojniski Vestnik-Journal of Mechanical Engineering,  Vol. 56, No. 7-8, (2010), 447-454.

4.      Thiagarajan, C., Sivaramakrishnan, R. and Somasundaram, S., "Modeling and optimization of cylindrical grinding of al/sic composites using genetic algorithms", Journal of the Brazilian Society of Mechanical Sciences and Engineering,  Vol. 34, No. 1, (2012), 32-40.

5.      Pal, D., Bangar, A., Sharma, R. and Yadav, A., "Optimization of grinding parameters for minimum surface roughness by taguchi parametric optimization technique", International Journal of Mechanical and Industrial Engineering,  Vol. 1, No. 3, (2012), 74-78.

6.      George, L.P., Job, K.V. and Chandran, I., "Study on surface roughness and its prediction in cylindrical grinding process based on taguchi method of optimization", International Journal of Scientific and Research publications,  Vol. 3, No. 5, (2013), 201.

7.      Ganesan, M., Karthikeyan, S. and Karthikeyan, N., "Prediction and optimization of cylindrical grinding parameters for surface roughness using taguchi method", IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684, (2012), 39-46.

8.      Kumar, P., Kumar, A. and Singh, B., "Optimization of process parameters in surface grinding using response surface methodology", International Journal of Research in Mechanical Engineering & Technology (ISSN 2249-5762),  (2013).

9.      Sohal, N., Sandhu, C.S. and Panda, B.K., "Analyzing the effect of grinding parameters on mrr and surface roughness of EN24 and EN353 steel", Mechanica Confab,  Vol. 3, No. 5, (2014), 1-5.

10.    Manickam, M.M.J.S.M. and Kalaiyarasan, V., "Optimization of cylindrical grinding process parameters of OHNS steel (AISI 0-1) rounds using design of experiments concept",  (2014).

11.    Modanloo, V., Hasanzadeh, R. and Esmaili, P., "The study of deep drawing of brass-steel laminated sheet composite using taguchi method", International Journal of Engineering-Transactions A: Basics,  Vol. 29, No. 1, (2016), 103-112.

12.    Nikoi, R., Sheikhi, M. and Arab, N.B.M., "Experimental analysis of effects of ultrasonic welding on weld strength of polypropylene composite samples", International Journal of Engineering-Transactions C: Aspects,  Vol. 28, No. 3, (2014), 447-453.

13.    Djavareshkian, M., Esmaeili, A. and Safarzadeh, H., "Optimal design of magnetorheological fluid damper based on response surface method", International Journal of Engineering-Transactions C: Aspects,  Vol. 28, No. 9, (2015), 1359.

14.    Alimirzaloo, V. and Modanloo, V., "Minimization of the sheet thinning in hydraulic deep drawing process using response surface methodology and finite element method", International Journal of Engineering-Transactions B: Applications,  Vol. 29, No. 2, (2016), 264.

15.    Meyers, R.H. and Montgomery, D.C., "Response surface methodology", Process and Product Optimisation Using Design Experiments, second ed, Willey, New York,  (2002).

International Journal of Engineering
E-mail: office@ije.ir
Web Site: http://www.ije.ir