Temperature effects on grinding residual stress

Abstract

Residual stress is a key factor that influences the reliability, precision, and life of final products. Earlier studies have alluded to the fact that the grinding process is usually the source of a tensile residual stress on the part surface, while there exists a temperature level commonly referred to as the onset tensile temperature beyond which the tensile profile of residual stresses starts to be generated. In this paper, a physics-based model is proposed to predict the onset temperature as a function of residual stress on an analytical and quantitative basis. The predictive model is based on the temperature distribution function using a moving heat source approach. Then, the thermal stresses are calculated analytically using Timoshenko thermal stress theory [1] followed by an elastic-plastic relaxation condition imposed on these stresses, thus leading to the resulting residual stresses. The model-predicted results have been experimentally validated using data of the grinding of AISI52100 hardened steel with subsequent X-ray and Neutron diffraction measurements. The model was shown to predict the residual stress profile under given process conditions and material properties, therefore providing an analytical tool for grinding process planning and optimization based on the understanding of onset tensile temperature for control of tensile residual stresses. (C) 2014 Elsevier B.V.