Investigation on the Workpiece Surface Residual Stress in High Efficiency Deep Grinding with Ultra High Wheel Speeds

2011 ◽  
Vol 487 ◽  
pp. 24-28
Author(s):  
Tan Jin ◽  
D.J. Stephenson ◽  
X.M. Sheng
Keyword(s):  
Residual Stress ◽  
Plastic Deformation ◽  
Contact Time ◽  
High Efficiency ◽  
Ground Surface ◽  
Grinding Process ◽  
Combined Effects ◽  
Surface Residual Stress ◽  
Workpiece Surface ◽  
Short Contact Time

The residual stress on the ground surface of workpiece in high efficiency deep grinding (HEDG) has been investigated. It has been found that the mechanism in forming the ground surface residual stress in HEDG is much different to that in the conventional shallow cut grinding process. It is not a thermally dominant event as in most of the shallow cut grinding mode; it is instead driven by the combined effects of both the thermal and mechanical loadings. The compressive plastic deformation near the workpiece surface during grinding and the short contact time in the HEDG regime, makes it possible to generate compressive surface stresses even when the surface temperatures are above 700-800°C.

Study on Influential Factors of Grinding Surface Residual Stress in Dry for Controlling Workpiece Surface Integrity

2016 ◽  
Vol 874 ◽  
pp. 362-367
Author(s):  
Xiu Ming Zhang ◽  
Shi Chao Xiu ◽  
Li Juan Liu ◽  
Xiao Liang Shi
Keyword(s):  
Residual Stress ◽  
Surface Integrity ◽  
Ground Surface ◽  
Element Model ◽  
Influential Factors ◽  
Grinding Process ◽  
Residual Tensile Stress ◽  
Surface Residual Stress ◽  
Workpiece Surface ◽  
Mechanical Field

Surface integrity of workpiece, especially residual stress, has the significant effects on the precision, the reliability and the fatigue life of the mechanical products. Since the most of final surface integrity of workpiece depends on the grinding process in engineering, this paper analyzed the ground surface residual stress through simulation and experiment. Based on the finite element model, the coupling of thermal mechanical field of plane grinding was simulated. The effects of grinding parameters on residual stress were studied compared to the experiment results. In addition, some measures for reducing the residual tensile stress of workpiece surface in the grinding process were put forwarded.

Analysis of the Surface Residual Stress in Grinding Aermet100

2011 ◽  
Vol 704-705 ◽  
pp. 318-324
Author(s):  
Y.Q. Xu ◽  
T. Zhang ◽  
Y.M. Bai
Keyword(s):  
Residual Stress ◽  
Plastic Deformation ◽  
Thermal Expansion ◽  
Tensile Stress ◽  
Heat Source ◽  
Residual Stresses ◽  
Surface Grinding ◽  
Grinding Process ◽  
Surface Residual Stress ◽  
Abrasive Grains

Grinding induces residual stresses, which can play an important role on the fatigue of the component. In general, residual stresses in a ground surface are primarily generated due to three effects: thermal expansion and contraction during grinding, plastic deformation caused by the abrasive grains of the wheel and phase transformations due to high grinding temperature. It was found that thermal expansion and plastic deformation in the grinding process were the major causes of residual stresses. In this paper, an analysis model for the calculation of residual stresses induced by a surface grinding process on an ultrahigh-strength steel (Aermet100) workpiece is presented. Firstly, the stress distribution induces by thermal expansion was obtained base on the transient heat conduction equation and the thermal properties of Aermet100. All the calculations were based on the moving heat source solution which was modeled as a uniformly distributed, 2D heat source moving across the surface of a half-space, found in Carslaw and Jaeger. The results show that the near surface residual stress is predominantly tensile and that the magnitude of this stress increases with increasing heat flux values. Secondly, the plastic deformation caused by the abrasive grains of the wheel was simulated base on the grain-workpiece interaction. The chip formation process and the material removal mechanisms can be examined using the micro-scale approach. The results show that the residual stress induced by the grinding force itself is generally compressive which is smaller than the residual tensile stress induced by thermal stress. Therefore, the residual stress brought about by grinding operation is generally a tensile stress. This paper offers an insight into the mechanism understanding of thermal and mechanical residual stresses induced by surface grinding. Key words: grinding, residual stress, grain

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.

Test Research on the Surface Residual Stress of Dimensional Ultrasonic Vibration Grinding for Al2O3/ZrO2(n)

2011 ◽  
Vol 295-297 ◽  
pp. 78-82
Author(s):  
Yan Wu ◽  
Er Geng Zhang ◽  
Wen Zhong Nie
Keyword(s):  
Residual Stress ◽  
Tensile Stress ◽  
Ultrasonic Vibration ◽  
Ground Surface ◽  
Ductile Deformation ◽  
Grinding Wheel ◽  
Ceramic Surface ◽  
Two Dimensional ◽  
Surface Residual Stress ◽  
Xrd Diffraction

Based on the research for the structure of the ceramic nanocomposites’ intragranular for Al2O3/ZrO2(n)，we did the test by the workpiece two-dimensional vibration grinding(WTDUVG), and focus on analyzing the characteristic and the effect element of the two-dimensional ultrasonic vibration grinding ceramic surface residual stress by the XRD diffraction. The result show that ceramic dimensional ultrasonic vibration grinding surface tensile stress is less than the same conventional grinding (CG) surface under tensile stress; two-dimensional ultrasonic vibration grinding surface residual compressive stress than conventional ground surface residual stress under the same grinding. Material removal mechanism of the grinding nature of the surface residual stress, when the material removaled by ductile deformation, grinding surface equal residual stress; when the material removaled by brittle- ductile mixed mode, the grinding surface tensile stress reduced, because the fracture of the ground surface, tensile stress released. As a results, the grit size of grinding wheel, Grinding depth and workpiece mechanical properties are the main technology factors affected the nature and size of the residual stress of ground surface.

The Formation and Behaviour of Residual Stresses with Finished Surfaces

2016 ◽  
Vol 686 ◽  
pp. 63-67
Author(s):  
Frantisek Holešovsky ◽  
Radek Lattner ◽  
Martin Novák ◽  
Milan Dian
Keyword(s):  
Residual Stress ◽  
High Pressures ◽  
Load Capacity ◽  
Ground Surface ◽  
Plastic Deformations ◽  
Workpiece Surface ◽  
Dimension Stability ◽  
Machine Parts ◽  
Stress Influences

The single tool grains affect the workpiece surface during grinding in the separated areas of deformation. The elastic and consequently plastic deformations occur at the engagement of grains. The friction of grain and material likewise the friction of elementary chip and grain acts simultaneously. These phenomena are accompanied with an origination of great amount of heat and high pressures and that is the reason for residual stress origin and formation in the ground surface. The residual stress is an important factor in influencing usable properties of machine parts. The stress influences not only the dynamical load capacity of surface but the durability and quality of design units as well. This stress is considered as the source of so called technological notches, having an influence on corrosion resistance, wear resistance, and dimension stability of machine parts.

Characteristic of Residual Stress Distributions at Workpiece Surface in Grind-Hardening

2014 ◽  
Vol 494-495 ◽  
pp. 624-627 ◽  
Author(s):  
Gui Cheng Wang ◽  
Chong Lue Hua ◽  
Jun Feng Zou ◽  
Hong Jie Pei ◽  
Juan Huang
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Phase Transformation ◽  
Grinding Process ◽  
Good Precision ◽  
Stress Distributions ◽  
Workpiece Surface ◽  
Finite Element Software ◽  
Grind Hardening ◽  
Transformation Stress

The grinding process is currently used for machining the parts requiring for good precision. However, the apparition of some damage related to this process is still uncontrolled, in which the major deterioration is from the residual stress. Through grinding and hardening test, the residual stress distributions under different grinding speeds are obtained, and then numerical simulation for thermal stress of the workpiece surface is carried out by finite element software ANSYS to deduce the distribution of phase transformation stress under different grinding speed.

Research on Residual Stress of Engineering Ceramic Grinding Surface

2013 ◽  
Vol 345 ◽  
pp. 259-262
Author(s):  
Wei Xiang Liu
Keyword(s):  
Residual Stress ◽  
Plastic Deformation ◽  
Stress Test ◽  
Diffraction Method ◽  
X Ray Diffraction ◽  
Surface Residual Stress ◽  
Stress Effects ◽  
Deformation Phase ◽  
Hard And Brittle Materials ◽  
Ceramic Grinding

As a kind of special hard and brittle engineering materials, in the grinding process, ceramic parts are prone to product cracks which affect seriously on the strength of the parts, and the residual stress is the main reason for cracks producting. Grinding parameters, grinding force and grinding temperature have a certain impact on the residual stress, and the residual stress effects on the fracture strength and fatigue strength of parts. ceramic grinding surface residual stress are caused by the combined effect, like plastic deformation, phase change, the microscopic plastic deformation of the material and the cold burnishing. The residual stress test several methods have X-ray diffraction method, perturbation degree method, indentation fracture. thermal elastic-plastic finite element method can be used to calculate grinding surface residual stress on ceramic and other hard and brittle materials.

Study on Residual Stress Distribution in Surface Grinding

2011 ◽  
Vol 487 ◽  
pp. 49-53 ◽  
Author(s):  
Gui Cheng Wang ◽  
Chong Lue Hua ◽  
Ju Dong Liu ◽  
Hong Jie Pei ◽  
Gang Liu
Keyword(s):  
Residual Stress ◽  
Plastic Deformation ◽  
Phase Transformation ◽  
Material Properties ◽  
Residual Stress Distribution ◽  
Wheel Speed ◽  
Temperature History ◽  
Good Precision ◽  
Surface Residual Stress ◽  
Key Factor

The grinding process is currently used for most of the parts requiring good precision. However, the apparition of some damage related to this process is still uncontrolled. The major deterioration is from residual stress. In order to investigate the residual stresses caused by mechanical plastic deformation, thermal plastic deformation and phase transformation in ground components, a feasible numerical method was developed to accommodate appropriately thermal stress and phase transformation in a workpiece experiencing critical temperature variation during grinding. The change of the material properties was modeled as function of temperature history. The wheel velocityVsis a key factor in determining the distribution of residual stress; both the surface residual stress and the depth of residual stress are induced with the increase of the wheel speed.

A Review High-Speed Milling of Meshing Cylindrical Surface

2012 ◽  
Vol 723 ◽  
pp. 82-86
Author(s):  
Pu Zhang ◽  
Pei Quan Guo ◽  
Yan Ke Cao ◽  
Xiao Wei Wang
Keyword(s):  
Residual Stress ◽  
Fatigue Strength ◽  
Surface Quality ◽  
Cylindrical Surface ◽  
High Speed ◽  
Metal Cutting ◽  
Surface Residual Stress ◽  
Surface Strength ◽  
Workpiece Surface ◽  
High Speed Milling

Meshing cylindrical surface always bears the alternating stress in the practical application. It will bring fatigue failure and fracture phenomena if the alternating stress is uncontroled, seriously affect the service life of the mechanical devices. The fatigue strength of the workpiece will be improved to boost the surface quality and surface strength and use the way of controling the workpiece surface residual stress brought by metal cutting to compressive stress. High-speed milling technology can greatly enhance the surface strength and surface quality of the workpiece surface, it can also change the cutting parameters to control the residual stress of the workpiece surface, so that it can greatly improve the fatigue strength of the workpiece.

Investigation of Surface Integrity in Conventional Grinding of Ti-6Al-4V

2010 ◽  
Vol 126-128 ◽  
pp. 899-904 ◽  
Author(s):  
Guo Giang Guo ◽  
Zhi Qiang Liu ◽  
Xiao Jiang Cai ◽  
Qing Long An ◽  
Ming Chen
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Surface Integrity ◽  
Ground Surface ◽  
Surface Residual Stress ◽  
Machined Surface ◽  
Conventional Grinding ◽  
Metallurgical Structure ◽  
Mechanical Factors ◽  
Deformation Layer

This paper investigates the surface integrity of Ti-6Al-4V in conventional grinding using SiC abrasive, it includes surface roughness, surface topography, surface residual stress and metallurgical structure alteration. The experiment result indicated that grinding depth and feed rate have significant effect on surface roughness. Workpiece ground surface was free of crack, but severe plastic deformation layer and light burn appeared because of chemical reactions and mechanical factors. Ground surface was in a state of high tensile residual stress, thermal cycling of surface layer had the greatest effect. The machined surface experienced microstructure alteration on the top layer of ground surface, a heat-affected zone (HAZ) was observed.

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