Cylindrical Grinding Parameters for Surface Quality, Grinding Force, and Wheel Wear Using Taguchi Method and ANOVA in Wet and Dry Conditions

This paper presents a systematic experimental investigation into the optimisation of cylindrical grinding process parameters for AISI 52100 bearing steel using the Taguchi L9 orthogonal array design and Analysis of Variance (ANOVA). Two grinding environments — dry and wet (flood coolant) — were evaluated at three levels of wheel speed (1800, 2400, 3000 rpm), work speed (50, 100, 150 rpm), and depth of cut (0.01, 0.02, 0.03 mm) using an aluminium oxide (Al₂O₃) vitrified bonded grinding wheel. Response variables measured include ground surface roughness (Ra), tangential grinding force (Ft), and specific wheel wear (G-ratio). Signal-to-Noise (S/N) ratio analysis identified the optimal parameter combination as wheel speed 3000 rpm, work speed 100 rpm, depth of cut 0.01 mm, and wet grinding. ANOVA revealed wheel speed as the most significant factor for surface roughness with 39.8 percent contribution, followed by depth of cut (32.4 percent) and work speed (18.6 percent). Wet grinding reduced surface roughness by 44.7 percent and improved G-ratio by 61.2 percent compared to dry grinding. Confirmation experiments validated predicted optimal values with errors below 3.9 percent