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Investigation of cutting mechanism and residual stress state with grooved grinding wheels

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Abstract

Grooved grinding wheels play an important role in reducing grinding thermal damage. Aluminum oxide grinding wheels of approximately 1 mm slot width and 35% groove ratio were successfully fabricated using a novel reciprocating ultrafast laser scanning mode to improve the grinding stability. Grinding experiments with grooved and non-grooved wheels were conducted on 42CrMo. The cutting mechanisms of grooved structures were analyzed with the established cutting kinematics of the abrasives in the groove edges and the grinding force components model. The decreased grinding forces were observed and analyzed with abrasive cutting mechanisms, indicating that grooved structures can increase the undeformed chip thickness of grains at the slot edges and decrease the specific grinding energy by reducing the specific plowing and sliding energy. The grooved grinding wheels exhibited high performance in inhibiting grinding heat and workpiece burns. The burned workpiece ground with non-grooved wheels experienced a phase transformation and had a high tensile residual stress state on the ground surface and subsurface, while compressive residual stresses were detected on the unburned workpiece surface ground with grooved wheels. Grooved grinding wheels can improve the grinding quality of workpieces due to the lower grinding temperature and residual stress.

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Funding

This work was supported by the National Natural Science Foundation of China under Grant Nos. U20A20284 and 52075323.

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Authors and Affiliations

  1. School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, China

    Zhibao Hou, Xifang Zhang & Zhenqiang Yao

  2. State Key Laboratory of Mechanical System and Vibration, Shanghai, China

    Zhenqiang Yao

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  1. Zhibao Hou
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  2. Xifang Zhang
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Contributions

Zhibao Hou was involved in conceptualization, methodology, investigation, experimental measurement, data curation, and writing—original draft. Xifang Zhang was involved in investigation, experimental measurement, and data curation. Zhenqiang Yao was involved in conceptualization, methodology writing—review and editing, project administration, and funding acquisition.

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Correspondence to Zhenqiang Yao.

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Hou, Z., Zhang, X. & Yao, Z. Investigation of cutting mechanism and residual stress state with grooved grinding wheels. Int J Adv Manuf Technol 128, 1455–1471 (2023). https://doi.org/10.1007/s00170-023-11933-w

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  • DOI: https://doi.org/10.1007/s00170-023-11933-w

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