According to the grind-hardening test and using the multiple linear regression analysis, the empirical formula of the tangential grinding force is established in this paper. Combined with the heat distribution coefficient formula of Rowe and Pettit, the thickness of the grind-hardening layer is predicted by using the finite element method under different grinding parameters. It draws the influence law of the grinding speed, cutting depth and feed rate to the thickness of the grind-hardening layer. It provided the basis to the drawing up, the application and the optimization of the grind-hardening process.

Grind-hardening machining is not only a complex process coupling mechanical, dynamical and thermal effects, but a process containing distinct changes of microstructure and properties of the workpiece grinded surface layer. Under the defined experimental conditions, an empirical formula was constituted to describe the relation between hardened layer depth and grinding parameter of grind-hardening layer, and the multi-parametric optimization was conducted. A commercial FEM software package was used to simulate the grind-hardening process. The distribution and variation characteristics of the temperature and microstructure in the grinded surface layer of workpiece were obtained and the forming mechanism of the grind-hardened layer is revealed.

Based on grind-hardening experiments, the two side-direction burrs were studied. Three main stages (burr generation, augmentation and formation) in the burr yielding process were clarified and the varying laws of burr morphologies and dimensions were systematically revealed. In turn raises, some new technologies, processes and methods of actively controlling burrs were put forward.