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Investigate on distribution and scatter of surface residual stress in ultra-high speed grinding

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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.

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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

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  • DOI: https://doi.org/10.1007/s00170-014-6128-5

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