Surface integrity investigation including grinding burns using barkhausen noise (BNA)

It is known that the grinding burns are function of grinding parameters and several other phenomena, which contribute to heat generation and its dissipation. The main objective of this work is to analyze the effect of grinding parameters on the integrity of ground surfaces with emphasis on grinding burns using Barkhausen noise analysis (BNA) and other characteristics such as residual stresses, surface roughness and dimensional stability. This study undertakes novel experimental approach for finding practical remedies that are often invoked to avoid problem of grinding burns. The work was performed in three stages, screening experiments provided a focused set of parameters to the experimentation using response surface methodology (RSM) followed by validation experiments. It is observed that, the work speed mainly governs the BNA value in grinding. At the same time, the wheel speed has the most prominent influence in minimizing surface roughness. Spark-out time, which tends to remove elastic deflection from the system, appears to be the most significant factor in minimizing the form error. It was evident that at lower work speeds and at higher depths of cut during the fine finish grinding, a reduction in spark-out time, leads to sever thermal damages thereby increasing the BNA value above 90 mp.