The objective of this research work is to investigate the practicality of magnetic workholding of non-magnetic synthetic quartz during high-speed grinding. This research work is sponsored by Quartzdyne and will be used as the starting point to applying single-piece rounding of its quartz. Hypotheses were created that would permit the authors to conclude that magnets are in fact worthwhile workholders for non-magnetic materials. Designs of Experiments were used to reject or fail to reject the null hypotheses. Experiments were carried out using a custom HAAS lathe, modified into a grinding center with an NSK live spindle, and neodymium-iron-boron magnets used to obtain both the holding and shear forces. Lastly, purchased polyolefin foam bumpers were used to increase the shear force, values were obtained with the Starrett force measurement machine. Input variables for the Design of Experiments (DOE) comprised of the holding force, feed-rate, part rotation, and in-feed size of cuts. Sample rotation relative to the magnets was the singular output variable. Experimental results were fitted with the correct distribution and modeled. Once a statistically significant model was attained input settings that minimized quartz sample rotation were determined and used to create an optimized program. Two sets of experiments were needed before the data could be properly fitted with a model. Thirteen out of fifteen samples remained stationary during the optimized program, which was adequate in failing to reject the second null hypothesis; a static sample at 350 RPM will remain static when undergoing high-speed rounding of its outside perimeter. Comparison of cycle times was crucial in reaching this conclusion; in fact, the cycle time of 7 minutes and 58 seconds for the optimized program was substantially less than Quartzdyne's estimated batch flow per piece cycle time of around 15 minutes. Obtaining a model was not possible or needed for the first hypothesis due to all experiments having zero rotation, therefore the authors also failed to reject the first null hypothesis; a static sample sandwiched between two permanent magnets with adequate holding force will remain stationary during rotation (min 250 RPM) Larger in-feed size cuts are possible when the quartz is square in shape –interrupted cuts. As it becomes cylindrical, cuts were reduced to experimental levels. Also, due to the amount of material being removed, the resin bonded wheel required dressing, without it rotation is expected. Variation was noticed while quantifying the shear force; it is attributed to the polyolefin foam bumper with its inconsistent coefficient of friction. A more uniform material, which can provide repeatable shear force values, would lessen the variation. All optimized program samples turned out perfectly round- even the two that had slight rotation.
| Identifer | oai:union.ndltd.org:BGMYU2/oai:scholarsarchive.byu.edu:etd-6614 |
| Date | 01 December 2014 |
| Creators | Basic, Saudin |
| Publisher | BYU ScholarsArchive |
| Source Sets | Brigham Young University |
| Detected Language | English |
| Type | text |
| Format | application/pdf |
| Source | Theses and Dissertations |
| Rights | http://lib.byu.edu/about/copyright/ |
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