Abstract
It is well known that grinding is a useful method to achieve a desired surface roughness for a WC-10Co-4Cr coating, deposited by high velocity oxygen fuel. In this study, the residual stress of the ground coating was determined via the x-ray diffraction technique, using the \(\sin^{2} \psi\) method and finite element method (FEM). The chemical layer removal process was used to experimentally measure the residual stress through the coating thickness. In finite element modeling of the grinding process, the temperature distribution of workpiece was initially determined by applying the heat flux obtained from grinding process. Then, the workpiece was cooled down to the ambient temperature. The temperature history of the thermal analysis was then used as an input to the stress modeling. The distribution of residual stress was finally determined by applying the grinding forces and residual stresses induced by the HVOF process. The experimental results, in accordance with the simulation results, illustrate that after the grinding process, the compressive residual stress of the coating surface increased significantly. The increase in residual stress after grinding was observed only to a specific depth of coating, measured from the surface. Below this depth, no increase was observed in compressive stress, up to the coating-substrate interface.
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Abbreviations
- \(a_{{\text{p}}}\) :
-
Depth of cut
- \(b_{{{\text{wp}}}}\) :
-
Width of cut
- \(c\) :
-
Specific heat capacity
- \(C\) :
-
Correction factor for temperature solution taking account of Peclet number, flux distribution and geometry
- \(d_{{\text{s}}}\) :
-
Diameter of the grinding wheel
- \(E_{{\text{s}}}\) :
-
Elastic module of the grinding wheel
- \(E_{{{\text{wp}}}}\) :
-
Elastic module of the workpiece
- \(E^{*}\) :
-
Equivalent elastic modulus for two bodies in contact
- \(F_{{\text{n}}}\) :
-
Normal force
- \(F_{{\text{t}}}\) :
-
Tangential force
- \(h_{{{\text{ch}}}}\) :
-
Convection coefficient of the chips
- \(h_{{\text{f}}}\) :
-
Convection coefficient of the cooling fluid
- \(h_{{{\text{wp}}}}\) :
-
Convection coefficient of the workpiece
- \(k\) :
-
Thermal conductivity
- \(k_{{\text{g}}}\) :
-
Density of the abrasive grains on the grinding wheel
- \(l_{{\text{c}}}\) :
-
Actual contact length
- \(l_{{\text{f}}}\) :
-
Contact length due to the force arising from deflection
- \(l_{{\text{g}}}\) :
-
Geometric contact length
- P :
-
Grinding power
- \(Pe\) :
-
Peclet number
- \(q_{{{\text{ch}}}}\) :
-
Chip heat flux
- \(q_{{\text{f}}}\) :
-
Cooling fluid heat flux
- \(q_{{\text{S}}}\) :
-
Grinding wheel heat flux
- \(q_{{\text{t}}}\) :
-
Total heat flux
- \(q_{{{\text{wp}}}}\) :
-
Workpiece heat flux
- \(r_{0}\) :
-
Radius of abrasive grains
- \(R_{{\text{r}}}\) :
-
Roughness factor
- \(T_{\max }\) :
-
Maximum temperature of the workpiece
- \(T_{{{\text{mp}}}}\) :
-
Melting point
- \(v_{{\text{c}}}\) :
-
Cutting speed
- \(v_{{\text{w}}}\) :
-
Speed of the workpiece
- \(\alpha_{{{\text{wp}}}}\) :
-
Thermal diffusivity for the workpiece
- \(\beta_{{\text{f}}}\) :
-
Thermal effusivity for transient heat conduction of the cooling fluid
- \(\beta_{{{\text{wp}}}}\) :
-
Thermal effusivity for transient heat conduction of the workpiece
- \(\mu\) :
-
Grinding force ratio
- \(\vartheta_{{\text{s}}}\) :
-
Poisson's ratio of grinding wheel
- \(\vartheta_{{{\text{wp}}}}\) :
-
Poisson's ratio of the workpiece
- \(\rho\) :
-
Density
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Zoei, M.S., Farizeh, T. & Sadeghi, M.H. Effect of Grinding on the Distribution of Residual Stress through Thickness of WC-10Co-4Cr Coating Deposited by HVOF. J Therm Spray Tech 30, 1957–1967 (2021). https://doi.org/10.1007/s11666-021-01259-y
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DOI: https://doi.org/10.1007/s11666-021-01259-y