Abstract
The purpose of this study is to investigate the residual stress induced by ultra-high-speed grinding of difficult-to-machine materials considering the thermomechanical coupling effect that is generated due to the friction between diamond tool and workpiece’s surface. A three-dimensional finite element method taking the rotational motion of tool into account is proposed. The simulation consists of three operations including loading, unloading, and cooling. The influences of different grinding conditions (grinding speed and grinding depth) on the residual stress field are analyzed. Results show that the main grinding force comes from normal rather than tangential direction due to the tool’s negative rake angle and their ratio is in the range of 1.2 to 1.7. The residual stress state on the finished surface is either tensile or compressive depending on various grinding condition; even both states may exist simultaneously. Further study shows that the ultra-high speed grinding can obtain lower surface residual tensile stress comparing with the high-speed grinding. Besides, a larger grinding depth is not advantage for obtaining a better machined quality in subsurface layer as the tensile maximum principal stress is also larger. Finally, the effects of different grinding conditions on residual stress scatters are analyzed utilizing mathematical statistic method. Results show that both smaller grinding depth and higher grinding speed are beneficial to achieve a better consistency of residual stress.
Similar content being viewed by others
References
Ko TJ, Kim HS (2001) Surface integrity and machineability in intermittent hard turning. Int J Adv Manuf Technol 18(3):168–175
Mamalis AG, Kundrak J, Gyani K (2002) On the dry machining of steel surfaces using superhard tools. Int J Adv Manuf Technol 19(3):157–162
Sasahara H (2005) The effect on fatigue life of residual stress and surface hardness resulting from different cutting conditions of 0.45 % C steel. Int J Machine Tools Manuf 45(2):131–136
Zong WJ, Li D, Cheng K, Sun T, Liang YC (2007) Finite element optimization of diamond tool geometry and cutting-process parameters based on surface residual stresses. Int J Adv Manuf Technol 32(7–8):666–674
Shet C, Deng X (2003) Residual stresses and strains in orthogonal metal cutting. Int J Machine Tools Manuf 43(6):573–587
Tsuchida K, Kawada Y, Kodama S (1975) A study of the residual stress distributions by turning. Bull Jpn Inst Met 18:123–130
Umbrello D (2011) Influence of material microstructure changes on surface integrity in hard machining of AISI 52100 steel. Int J Adv Manuf Technol 54(9–12):887–898
Afazov SM, Becker AA, Hyde TH (2010) Effects of micro-stresses from machining and shot-peening processes on fatigue life. Int J Adv Manuf Technol 51(5–8):711–722
Tang L, Huang J, Xie L (2011) Finite element modeling and simulation in dry hard orthogonal cutting AISI D2 tool steel with CBN cutting tool. Int J Adv Manuf Technol 53(9–12):1167–1181
Bruni C, Celeghini M, Geiger M, Gabrielli F (2007) A study of techniques in the evaluation of springback and residual stress in hydroforming. Int J Adv Manuf Technol 33(9–10):929–939
Henriksen EK (1951) Residual stresses in machined surfaces. J Am Soc Mech Eng Trans 73(1):69–76
Hua J, Umbrello D, Shivpuri R (2006) Investigation of cutting conditions and cutting edge preparations for enhanced compressive subsurface residual stress in the hard turning of bearing steel. J Mater Process Technol 171(2):180–187
Brinksmeier E, Cammett JT, KoÈnig W, Leskovar P, Peters J, ToÈnshoff HK (1982) Residual stresses—measurement and causes in the machining process, Ann. CIRP 31(2):491–510
El-Helieby SOA, Rowe GW (1980) A quantitative comparison between residual stresses and fatigue properties of surface-ground bearing steel (EN31). Wear 58:155–172
Chen X, Roweb WB, McCormack DF (2000) Analysis of the transitional temperature for tensile residual stress in grinding. J Mater Process Technol 107:216–221
McCormack DF, Rowe WB, Chen X, Bouzina A, Fitzpatrick ME, Edwards L (2000) Characterising the onset of tensile residual stresses in ground components. Proceedings of the 6th International Conference on Residual Stresses, Oxford, p 225
Mahdi M, Zhang LC (1998) Applied mechanics in grinding—VI. Residual stresses and surface hardening by coupled thermo-plasticity and phase transformation. Int J Machine Tools Manuf 38:1289–1304
Kruszyński BW, Wójcik R (2001) Residual stress in grinding. J Mater Process Technol 109:254–257
Coto B, Navas VG, Gonzalo O, Aranzabe A, Sanz C (2011) Influences of turning parameters in surface residual stresses in AISI 4340 steel. J Adv Manuf Technol 53(9–12):911–919
Hua J, Umbrello D, Shivpuri R (2006) Investigation of cutting conditions and cutting edge preparations for enhanced compressive subsurface residual stress in the hard turning of bearing steel. J Mater Process Technol 171(2):180–187
Liu M, Takagi J-I, Tsukuda A (2004) Effect of tool nose radius and tool wear on residual stress distribution in hard turning of bearing steel. J Mater Process Technol 150(3):234–241
Ghanem F, Fredj NB, Sidhom H, Braham C (2011) Effects of finishing processes on the fatigue life improvements of electromachined surfaces of tool steel. Int J Adv Manuf Technol 52(5–8):583–595
Habak M, Lebrun JL (2011) An experimental study of the effect of high-pressure water jet assisted turning (HPWJAT) on the surface integrity. Int J Machine Tools Manuf 51(9):661–669
Wang F, Block JM, Chen WW, Martini A, Zhou K, Keer LM, Wang QJ (2009) A multi-level model for elastic–plastic contact between a sphere and a flat rough surface. J Tribol 131(2):021409
Chen WW, Zhou K, Keer LM, Wang QJ (2010) Modeling of elasto-plastic indentation on layered materials using equivalent inclusion method. Int J Solids Struct 47:2841–2854
Zhou K, Keer LM, Wang QJ, Ai X, Sawamiphakdi K, Glaws P, Paire M, Che F (2012) Interaction of multiple inhomogeneous inclusions beneath a surface. Comput Meth Appl Mech Eng 217–220:25–33
Zhou K, Keer LM, Wang QJ (2011) Semi-analytic solution for multiple interacting three-dimensional inhomogeneous inclusions of arbitrary shape in an infinite space. Int J Numer Meth Engng 87:617–638
Zhou K, Wei R (2014) Multiple cracks in a half-space under contact loading. Acta Mech 225:1487–1502. doi:10.1007/s00707-013-1070-4
Zhou K, Chen WW, Keer LM, Wang QJ, Ai X, Sawamiphakdi K, Glaws P (2011) Multiple 3D inhomogeneous inclusions in a half space under contact loading. Mech Mater 43:444–457
Zhou K, Chen WW, Keer LM, Wang QJ (2009) A fast method for solving three dimensional arbitrarily-shaped inclusions in a half space. Comput Meth Appl Mech Eng 198:885–892
Zhou K, Keer LM, Wang QJ (2011) Analysis of hard coatings on a substrate containing inhomogeneities. J Mech Mater Struct 6:627–639
Zhou K, Wei RB (2014) Modeling cracks and inclusions near surfaces under contact loading. Int J Mech Sci 83:163–171
Dong QB, Zhou K (2014) Elastohydrodynamic lubrication modeling for materials with multiple cracks. Acta Mech. doi:10.1007/s00707-014-1145-x
Hamdi H, Zahouani H, Bergheau JM (2004) Residual stresses computation in a grinding process. J Mater Process Technol 147:277–285
Qin MY, Ye BY, Jia X, He AD (2013) Experimental investigation of residual stress distribution in pre-stress cutting. Int J Adv Manuf Technol 65:355–361
Cao XY, Lin B, Zhang XF (2013) A study on grinding surface waviness of woven ceramic matrix composites. Appl Surf Sci 270:503–512
Linz M, Winkelmann H, Hradil K, Badisch E, Mücklich F (2013) Directional development of residual stress and surface fatigue during sliding contact. Eng Fail Anal 35:678–685
Johnson RA, Miller I, Freund JE (1994) Probability and statistics for engineers. Prentice Hall, New Jersey
Little RE, Jebe EH (1975) Statistical design of fatigue experiments. Applied Science Publishers, London
Azarhoushang B, Tawakoli T (2011) Development of a novel ultrasonic unit for grinding of ceramic matrix composites. Int J Adv Manuf Technol 57:945–955
Liu CR, Yang XA (1999) New perspective of residual stress induced by machining and grinding. Proc ASME Manuf Eng Div 10:807–816
Liu CR, Yang XP (2001) The scatter of surface residual stressed produced by face-turning and grinding. Mach Sci Tech 5(1):1–21
Doman DA, Warkentin A, Bauer R (2009) Finite element modeling approaches in grinding. Int J Machine Tools Manuf 49:109–116
Yang X, Liu CR, Grandt AF (2002) An experimental study on fatigue life variance, residual stress variance, and their correlation of face-turned and ground Ti 6Al-4V samples. J Manuf Sci Eng 124(4):809–819
Cockcroft MG, Latham DJ (1968) Ductility and the workability of metals. J I Met 96:33–39
Filice L, Micari F, Rizzuti S, Umbrello D (2007) A critical analysis on the friction modeling in orthogonal machining. Int J Machine Tools Manuf 47:709–714
Macherauch E, Wohlfahrt H (1973) Zur zweckmäßigen definition von eigenspannungen. Härterei-Tech Mitt 28:201–211, 28: 201–211
Li BZ, Ni JM, Yang JG (2014) Study on high-speed grinding mechanisms for quality and process efficiency. Int J Adv Manuf Technol 70:813–819
Mao C, Zhou ZX, Ren YH, Zhang B (2010) Analysis and FEM simulation of temperature field in wet surface grinding. Mater Manuf Process 25:399–406
Mao C, Zhou ZX, Zhang J, Huang XM, Gu DY (2011) A comparative research of damaged layers formed in surface grinding and wire-electrodischarge machining. Mater Manuf Process 26:1473–1480
Mao C, Zhou ZX, Zhang J, Huang XM, Gu DY (2011) An experimental investigation of affected layers formed in grinding of AISI 52100 steel. Int J Adv Manuf Technol 54:515–523
Thiele JD, Meikote SN, Peascoe RA, Watkins TR (1999) Effect of cutting-edge geometry and workpiece hardness on surface residual stresses in finish hard turning of AISI 52100 steel. J Manuf Sci Eng, ASME 122:642–649
Field M, Koster WP, Kohls JB, Snider RE, Maranchik JJ (1970) Machining of high strength steels with emphasis on surface integrity. Air Force Machinibility Data Center, Report No. AFMDC 70–1
Dölle H, Cohen JB (1980) Evaluation of (residual) stresses in textured cubic metals. Metall Mater Trans A 11:159
El-Helieby SOA, Rowe GW (1980) A quantitative comparison between residual stresses and fatigue properties of surface-ground bearing steel (En 31). Wear 58:155
Malkin S (1989) Grinding technology theory and applications of machining with abrasives. Ellis Horwood, Chichester
Shaw MC (1996) Principles of abrasive processing. Oxford Science, Oxford
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Chen, J., Fang, Q. & Zhang, L. Investigate on distribution and scatter of surface residual stress in ultra-high speed grinding. Int J Adv Manuf Technol 75, 615–627 (2014). https://doi.org/10.1007/s00170-014-6128-5
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-014-6128-5