Abstract
In this work, we present a fully atomistic approach to modeling a finishing process with the goal to shed light on aspects of work piece development on the microscopic scale, which are difficult or even impossible to observe in experiments, but highly relevant for the resulting material behavior. In a large-scale simulative parametric study, we varied four of the most relevant grinding parameters: The work piece material, the abrasive shape, the temperature, and the infeed depth. In order to validate our model, we compared the normalized surface roughness, the power spectral densities, the steady-state contact stresses, and the microstructure with proportionally scaled macroscopic experimental results. Although the grain sizes vary by a factor of more than 1,000 between experiment and simulation, the characteristic process parameters were reasonably reproduced, to some extent even allowing predictions of surface quality degradation due to tool wear. Using the experimentally validated model, we studied time-resolved stress profiles within the ferrite/steel work piece as well as maps of the microstructural changes occurring in the near-surface regions. We found that blunt abrasives combined with elevated temperatures have the greatest and most complex impact on near-surface microstructure and stresses, as multiple processes are in mutual competition here.
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Acknowledgements
This work was funded by the Austrian Research Promotion Agency FFG (Project SyFi, No. 864790). Part of this work was funded by the Austrian COMET-Program (Project K2 InTribology1, No. 872176) and carried out at the “Excellence Centre of Tribology”. The computational results presented have been achieved using the Vienna Scientific Cluster (VSC). The government of Lower Austria is gratefully acknowledged for financially supporting the endowed professorship tribology at the Vienna University of Technology (Grant No. WST3-F-5031370/001-2017) in collaboration with AC2T research GmbH. The authors wish to thank Katharina Newrkla and Ulrike Cihak-Bayr for performing topography measurements of the experimental work pieces and providing pre-processed data for the PSD evaluations. Open access funding was provided by Vienna University of Technology (TU Wien).
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S. J. EDER. He received his Ph.D. degree in technical physics in 2012 for the atomistic simulation of mixed- and boundary-lubricated friction contacts. Since 2007, he has been working at Excellence Centre of Tribology (AC2T research GmbH), first as a project manager and now also as principal scientist. In 2015, he received a research grant to simulate abrasive processes occurring during polishing and grinding at multiple length scales. Since 2018, he is also active as a research associate in Carsten Gachot’s tribology group at Vienna University of Technology (TU Wien). His research interests include near-surface microstructural development of polycrystalline metals in sliding contacts and in finishing processes.
P. G. GRÜTZMACHER. He received his Ph.D. degree in materials science in 2019 from Saarland University under the guidance of Frank Mücklich (Institute of Functional Materials) for the tribological investigation of multi-scale surface textures. Since 2019, he works in Carsten Gachot’s tribology group at TU Wien as postdoctoral researcher. His current research interests focus on near-surface microstructural development of polycrystalline metals during sliding, tribological mechanisms of 2D materials, and surface engineering.
T. SPENGER. He obtained bachelor and master degrees at Graz University of Technology with a specialization in production science and automotive engineering. He has several years of practical experience as a project engineer in the automotive testing industry. Since 2017, he is enrolled in the doctoral program in mechanical engineering as a university assistant at Graz University of Technology with a specialization in grinding technology.
H. HECKES. He studied mineralogy at RWTH Aachen University. He started working at Saint-Gobain Abrasives in 2006 as a researcher on the functionality of vitrified grinding wheels. This was also the topic of his diploma thesis in 2008, focusing on the resulting system strength of different glass matrices based on external influences. He continued working in this area of expertise at Tyrolit Schleifmittelwerke Swarovski K.G. as product developer and group leader for vitrified conventional tools. He specializes in the analysis of chemical and physical interactions between bond matrix and grain.
H. ROJACZ. He is a senior scientist at Austrian Centre of Competence for Tribology. His educational background is materials science as well as energy- and environmental science. He has more than ten years’ experience in materials tribology and materials analysis techniques such as scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD). His research is mainly focused on high-temperature wear, wear-resistant coatings, and microstructural changes in tribological contacts.
A. NEVOSAD. He received his Ph.D. degree in materials science in 2013 from Montanuniversität Leoben for conductive probe based investigations on ZnO varistor ceramics. Since 2014, he is employed at AC2T research GmbH, first as project manager in the field of wear reduction and since 2020 as leader of the research area “friction optimized devices”. His research activities comprise wear and friction phenomena on various materials like metals, polymers, and coatings in various load conditions and environments.
F. HAAS. He studied mechanical engineering and economics and received his Ph.D. degree from Graz University of Technology in 1996. Afterwards he was managing director in the family-owned mechanical engineering company. From 1997 on, he also taught at University of Applied Sciences Campus 02, where he worked as a mechanical engineering professor from 2007 to 2013. He was appointed head of the Institute for Production Engineering at TU Graz in 2013. Since 2020, he holds the position of the faculty dean of mechanical engineering and economic sciences at Graz University of Technology.
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Experimentally validated atomistic simulation of the effect of relevant grinding parameters on work piece topography, internal stresses, and microstructure
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Eder, S.J., Grützmacher, P.G., Spenger, T. et al. Experimentally validated atomistic simulation of the effect of relevant grinding parameters on work piece topography, internal stresses, and microstructure. Friction 10, 608–629 (2022). https://doi.org/10.1007/s40544-021-0523-3
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DOI: https://doi.org/10.1007/s40544-021-0523-3