A Comparative Study of Residual Stress Distribution Induced by Hard Machining Versus Grinding

Abstract

This study investigates the residual stress distribution induced by hard machining and grinding and compares its impact on fatigue parameters. The residual stress distribution below hard turned and ground surfaces is investigated after a thermally damaged layer is removed. Fatigue parameters are computed based on the residual stress distribution to compare the impact of the residual stress distribution on the fatigue performance. Rolling contact fatigue tests are then performed to substantiate the computations. The effect of residual stresses on crack initiation depth is shown to be significant for the ground specimen. The maximum shear stress at crack initiation depth of the hard turned specimen is smaller than that of the ground specimen. Due to a significant increase in crack initiation life, the predicted rolling contact fatigue life of the hard turned specimen is longer than that of the ground specimen. The overall average in the ratios of predicted life to experimental life for the hard turned specimen is closer to 1 than that for the ground specimen. The results demonstrate that the hard turned specimen shows better rolling contact fatigue performance and better accuracy in the fatigue life prediction.

The Impact of Grinding on Surface Integrity of Powder-Metallurgy High-Speed Steel (S390)

“…Residual stress. The fatigue life of the workpiece, as well as the corrosion resistance, can be drastically compromised if large tensile residual stresses are present.The compressive residual stresses can make the nucleation and propagation offatigue cracks more difficult.In this experiment, all measured residual stressesarecompressive.The highest stress value reaches 739MPa.In comparison with previous studies [5,7,9,10],it can be concludedthat,there is a CRSF on ground surface of each sample,which is beneficial to the fatiguelife.…”

“…3) Phase transformation residual stresses. All three of these mechanisms may be present during the grinding of steel.Therefore,any residual stress found may be a superimposition of the three kinds.A few studies [5,7,9,10]proved thatthere is a compressive residual stresses field (CRSF) on thesurface under gentle grinding conditions. In order to get CRSF on ground surface, it is necessary to keep the mechanical action of abrasive grain dominant, and try to reduce the heat induced by friction action.CapelloandSemeraro [11]studied the effect of grinding parameters on residual stress profiles.Their studyshowed that theworkpiece feed rate does not seem to influence the residualstresses, while wheel wearand wheel dressing significantly affectthe level of residual stresses generated during machining.…”

Study on hardening mechanism in GH and PSHG based on classical nucleation theory

“…But the inner layer just has elastic deformation due to the pre-stress and it can restore after pre-stress is unloaded. Then the constraint effect to the surface will cause compressive residual stress within it to counteract the tensile residual stress which is caused by heating effect (Choi, 2009;Duscha et al, 2011). At last, its comprehensive result shows a compressive residual stress.…”

Transformation mechanism of microstructure and residual stress within hardening layer in PSHG

“…There are several main reasons of the generation of residual stress in hardening layer (Abdul Aziz, et al, 2013) (Karabelchtchikova, et al, 2008) (Choi, 2009) (Duscha, et al, 2011) (Tönissen, et al, 2012). The final residual stress is the comprehensive result of these factors.…”