Research on Grinding Residual Stresses on the Surface of Nanostructured Ceramic Coatings

2013 ◽  
Vol 709 ◽  
pp. 131-134
Author(s):  
Wei Xiang Liu ◽  
Zhong Yu Zhou
Keyword(s):  
Residual Stress ◽  
Corrosion Resistance ◽  
Fatigue Strength ◽  
Service Life ◽  
Residual Stresses ◽  
Ceramic Coatings ◽  
Grinding Process ◽  
Abrasive Wheel ◽  
Nanostructured Ceramic

Residual stress produced on the surface of nanostructured ceramic coatings when they were grinded by diamond superhard abrasive wheel, these residual stresses affected directly the fracture strength, fatigue strength and corrosion resistance of the ceramic parts, they affected the surface quality of machined ceramic parts, and thus they affected the working reliability and the service life of ceramic parts. The tests show that the distribution of residual stress is directional, the residual compressive stress can make the hardness of the material increase, they can reduce the wear rate of the material, for the tested specimen, grinding surface whole residual stress σ is the sum up original residual stress σ0(existed in the part’s surface ) and grinding residual stress Δσ (formed by grinding process.), σ=σ0+ Δσ.

Grinding Affect the Service Life of Mould Research

2013 ◽  
Vol 850-851 ◽  
pp. 225-228
Author(s):  
Fang He
Keyword(s):  
Residual Stress ◽  
Service Life ◽  
Cavity Surface ◽  
Grinding Process ◽  
Processing Quality ◽  
Micro Cracks ◽  
Close Relationship ◽  
Mould Cavity ◽  
Manufacturing Time

In the process of modern mould manufacturing, grinding work still account for 25% ~ 45% of the total manufacturing time mould. Mould manufacturing quality of the finished product is closely related to the precision of mould manufacturing, particularly with the mould cavity surface accuracy and surface roughness has a close relationship. In the manufacturing of mould to make grinding micro cracks and residual stress is reduced to a minimum, full attention, grinding process in order to improve the service life of mould. So research to improve grinding processing quality, improve the service life of the mold, to extend the time of service, has the positive significance

scholarly journals Study on the Effect of Grinding Pressure on Material Removal Behavior Performed on a Self-Designed Passive Grinding Simulator

2021 ◽  
Vol 11 (9) ◽  
pp. 4128
Author(s):  
Peng-Zhan Liu ◽  
Wen-Jun Zou ◽  
Jin Peng ◽  
Xu-Dong Song ◽  
Fu-Ren Xiao
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Service Life ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Temperature ◽  
Grinding Efficiency

Passive grinding is a new rail grinding strategy. In this work, the influence of grinding pressure on the removal behaviors of rail material in passive grinding was investigated by using a self-designed passive grinding simulator. Meanwhile, the surface morphology of the rail and grinding wheel were observed, and the grinding force and temperature were measured during the experiment. Results show that the increase of grinding pressure leads to the rise of rail removal rate, i.e., grinding efficiency, surface roughness, residual stress, grinding force and grinding temperature. Inversely, the enhancement of grinding pressure and grinding force will reduce the grinding ratio, which indicates that service life of grinding wheel decreases. The debris presents dissimilar morphology under different grinding pressure, which reflects the distinction in grinding process. Therefore, for rail passive grinding, the appropriate grinding pressure should be selected to balance the grinding quality and the use of grinding wheel.

Study Progress on Grinding Surface Residual Stresses for Nano-Ceramic Coatings

2013 ◽  
Vol 753-755 ◽  
pp. 277-280 ◽  
Author(s):  
Wei Xiang Liu
Keyword(s):  
Residual Stress ◽  
High Hardness ◽  
Ceramic Materials ◽  
Ceramic Coatings ◽  
Grinding Process ◽  
Monitoring And Control ◽  
Surface Residual Stress ◽  
Surface Residual Stresses ◽  
Process Monitoring And Control ◽  
Grinding Mechanism

Nano-ceramic materials had high hardness and wear resistance. Combined with current technology and cost saving, nanostructured coatings technology were carried out, using HVOF ( high velocity oxygen fuel) or plasma spraying technique can obtain high quality ceramic coating on metal substrate. Ceramic coatings produced cracks in the grinding due to grinding surface residual stress. the coatings grinding surface residual stress of engineering ceramics have been researched, grinding surface residual stress in the nanostructured ceramic coatings are being researched. the researches in this field include grinding process modeling, abrasives and grinding parameters, grinding process monitoring and control and realization of the software, the grinding mechanism and grinding damage on the surface, grinding force prediction, on-line detection, grinding on nanocoating material is a multivariable complex process.

Effect of Coating Process Parameters on the Development of Residual Stresses in Ceramic Coatings

2019 ◽  
Author(s):  
Ali Gadelmoula ◽  
Khaled Al-Athel
Keyword(s):  
Residual Stresses ◽  
Process Parameters ◽  
Elevated Temperatures ◽  
Ceramic Coatings ◽  
Interface Roughness ◽  
Fe Model ◽  
Computational Framework ◽  
Scientists And Engineers ◽  
Coating Layers

Abstract Ceramic coatings are widely used in many engineering applications, especially applications related to components operating at elevated temperatures. One of the main issues relates to ceramic coatings is the development of residual stresses due to quenching and the thermal mismatch between the deposited coating layers and the substrate. In this work, a computational framework is developed to investigate the effect of various process parameters on the development of the residual stresses. The geometry of the coating layers and the interface roughness between the layers is first generated using SimCoat, a Monte Carlo based statistical algorithm that determines the effect of process parameters (droplet size, spraying speed, etc.) on the characteristics of the developed coating (coating thickness, porosity, etc.). An in-house code is used to convert the statistical data into a finite element (FE) model. Various FE models are generated with different process parameters, and the development of residual stresses is compared between them. The developed framework can be used by material scientists and engineers to predict the quality of the coating and optimize the process parameters to any specific application.

scholarly journals Residual Stresses Induced by Surface Working and Their Improvement by Emery Paper Polishing

2020 ◽  
Vol 4 (2) ◽  
pp. 21
Author(s):  
Makoto Hayashi
Keyword(s):  
Residual Stress ◽  
Stainless Steel ◽  
Fatigue Strength ◽  
Residual Stresses ◽  
Diffraction Method ◽  
304 Stainless Steel ◽  
Heat Treated ◽  
Emery Paper ◽  
Type 304 ◽  
Type 304 Stainless Steel

In many of machine parts and structural components, materials surface would be worked. In this study, residual stresses on the surfaces were measured by X-ray diffraction method, and effects of surface working on the residual stresses were examined. In case of lathe machining of type 304 stainless steel bar, the residual stresses in circumferential directions are tensile, and those in axial directions are almost compressive. Highly tensile residual stresses in the circumferential directions were improved by emery paper polishing. 10 to 20 times of polishing changes high tensile residual stresses to compressive residual stresses. In the case of shot peening on a type 304 stainless steel plate, the compressive residual stress inside is several hundred MPa lower than that on the surface. By applying the emery paper polishing to the shot peened surface 10 or 20 times, the residual stress on the surface is improved to −700 MPa. While fatigue strength at 288 °C in the air of the shot peened material is 30 MPa higher than solution heat treated and electro-polished material, the fatigue strength of the shot peened and followed by emery paper polished material is 60 MPa higher. Thus, the emery paper polishing is simple and a very effective process for improvement of the residual stresses.

Surface Effects and Residual Stresses in Electrolytically Ground Steel

1962 ◽  
Vol 84 (4) ◽  
pp. 483-489 ◽  
Author(s):  
J. Frisch ◽  
R. R. Cole
Keyword(s):  
Residual Stress ◽  
Corrosion Resistance ◽  
Residual Stresses ◽  
Material Removal ◽  
Removal Rate ◽  
Stress Distributions ◽  
Electrolyte Flow ◽  
Surface Conditions ◽  
Mechanical Removal ◽  
Grinding Conditions

The effects of electrolytic grinding on surface conditions and residual stress characteristics has been experimentally investigated. Surface finish, uniformity of material removal, and corrosion resistance are found to be dependent on mechanical removal rate as determined by wheel downfeed as well as electrolyte flow rate. Downfeeds of approximately 0.002 in. in the process do not produce measurable residual stresses and therefore it was further established that electrolytic grinding with moderate downfeeds can be used in place of swab etching techniques for evaluation of residual stress distributions. The maximum residual surface stresses were found to be not more than 22,000 psi, well below the yield strength of the material and were induced during the most severe grinding conditions.

scholarly journals INFLUENCE OF THE GEOMETRIC CHARACTERISTICS OF THE DISCONTINUOUS PROFILE WORKING SURFACES OF ABRASIVE WHEELS FOR PRECISION AND TEMPERATURE WHEN GRINDING

2021 ◽  
pp. 115-125
Author(s):  
Oleksiy Yakimov ◽  
Liubov Bovnegra ◽  
Vladimir Tonkonogyi ◽  
Vladyslav Vaysman ◽  
Victor Strelbitskyi ◽  
...  
Keyword(s):  
Surface Layer ◽  
Heat Stress ◽  
Elastic System ◽  
Dynamic Interaction ◽  
Grinding Wheel ◽  
Stable Operation ◽  
Grinding Process ◽  
Abrasive Wheel ◽  
Working Surface

Grinding is the most common finishing method for hardened steel parts. Grinding is accompanied by a large heat release in the cutting area, under the influence of which structural changes appear in the thin surface of the processed parts, tensile stress and even microcracks, which significantly reduce the operational reliability of machines that include these parts. The use of abrasive wheels with an intermittent working surface makes it possible to reduce the temperature in the area of contact of abrasive grains with the material of the workpiece and, as a consequence, stabilize the quality of the surface layer of the workpieces. High-frequency vibrations in the elastic system of the machine, accompanying the work of an intermittent wheel, are a positive factor that reduces the energy consumption of the grinding process. However, under certain conditions of dynamic interaction of the tool with the workpiece, parametric resonance may occur, which worsens the geometric and physical-mechanical parameters of the quality of the surface layer of the processed part. The aim of the work is to realize the possibility of predicting the quality parameters of the surface layer of parts during intermittent grinding by studying the influence of the design features of the macrotopography of the working surface of abrasive wheels and processing modes on the nature of the dynamic interaction of the tool with the workpiece and the heat stress in the cutting area. It was found that the parametric vibrations of the elastic system of the machine tool can be shifted to a more stable area, due to an increase in the number of interruptions of the working surface of the abrasive wheel with a constant ratio of the length of the protrusions and depressions. The increase in the number of breaks on the wheel also contributes to a decrease in temperature in the cutting area. It was found that to maintain the stable operation of the elastic system of the machine, it is necessary to reduce the number of cavities on the grinding wheel with an increase in the cutting speed. However, both of these actions are accompanied by an increase in the heat stress of the grinding process. It has been experimentally established that for ordinary (pendulum) grinding, it is possible to achieve an increase in processing productivity by increasing the speed of the longitudinal movement of the table.

Experimental Investigation on Residual Stress of Model S1100 of Crankshaft Chamfer Based on XRD

2007 ◽  
Vol 353-358 ◽  
pp. 2301-2304
Author(s):  
Yong Kang Zhang ◽  
De Jun Kong ◽  
Jin Zhon Lu ◽  
Ai Xin Feng ◽  
Xu Dong Ren ◽  
...  
Keyword(s):  
Residual Stress ◽  
Experimental Investigation ◽  
Fatigue Life ◽  
Stress Distribution ◽  
Service Life ◽  
Residual Stresses ◽  
Fatigue Testing ◽  
Residual Stress Distribution ◽  
Isothermal Quenching ◽  
Main Factors

Residual stresses of model S1100 of crankshaft chamfer were measured by the technology of XRD. The distributions of residual stresses under mechanical peening, mechanical rolling and isothermal quenching are measured, and the tests of fatigue life were conducted. The results showed that the distribution of residual stress by machining in the crankshaft chamfer is complicated, which is at the tensile-compressive status, and it is one of the main factors to affect fatigue life of the crankshaft; isothermal quenching improves the distribution of residual stress, and tensile stress of the crankshaft chamfer is changed into the compressive stress, which may satisfy the requests of fatigue testing for 5 × 106 cycles. Although the mechanical rolling improved the residual stress distribution in the chamfer linked with the crank, tensile stresses in the chamfer connected with the linkage also increase, which influences the service life of the crankshaft.

Analysis of Residual Stress Induced by Hand Grinding Process

2011 ◽  
Vol 681 ◽  
pp. 327-331 ◽  
Author(s):  
Sawsen Youssef ◽  
O. Calonne ◽  
Eric Feulvarch ◽  
P. Gilles ◽  
Hédi Hamdi
Keyword(s):  
Residual Stress ◽  
Experimental Study ◽  
Crack Initiation ◽  
Residual Stresses ◽  
Material Removal Rate ◽  
Surface Integrity ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Process ◽  
Cup Wheel

Grinding cup wheel is often used in the case of hand grinding which allows an important material removal rate but with secondary concern of surface integrity. Integrity is strongly affected by the process and consequently influences the surface behaviour in terms of resistivity to stress corrosion and crack initiation. This operation is difficult to master in terms of results on the surface and subsurface due to its manual nature. The paper presents results of an experimental study to investigate the residual stresses induced by this hand grinding process.

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