Comprehensive analysis of the thermal impact and its depth effect in grinding

Heinzel, Carsten; Heinzel, Jonas; Guba, Nikolai; Hüsemann, T.

doi:10.1016/j.cirp.2021.04.010

Cited by 19 publications

(6 citation statements)

References 13 publications

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“…However, the determination of the exact time the temperature affects the workpiece material during grinding is complicated. A quantity for a rough estimation of the time of temperature impact on the workpiece surface and subsurface is the contact time t c , which in surface grinding corresponds to the geometric contact length l g divided by the tangential feed speed v ft [12,17,30]. In accordance with investigations by Takazawa [30], Figure 10 shows the observed hardness reduction as a function of the contact time for constant maximum temperatures.…”

Section: Evaluation Of Hardness Changes Due To Thermal Loadssupporting

confidence: 60%

“…High temperatures during grinding can lead to the grinding burn. The research of Malkin and Heinzel determined the thermal impact in order to identify a point at which grinding burn occurs [11,12]. In order to detect grinding burn, in-process Barkhausen noise measurements were used [12].…”

Section: Introduction and State Of The Artmentioning

confidence: 99%

“…The research of Malkin and Heinzel determined the thermal impact in order to identify a point at which grinding burn occurs [11,12]. In order to detect grinding burn, in-process Barkhausen noise measurements were used [12]. Baumgart used a two-color pyrometer to determine the temperatures during grinding [13].…”

Section: Introduction and State Of The Artmentioning

confidence: 99%

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Evaluation of Hardness and Residual Stress Changes of AISI 4140 Steel Due to Thermal Load during Surface Grinding

Kohls

Heinzel

Eich

2021

JMMP

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During surface grinding, internal material loads are generated, which take effect on the surface and subsurface zone of AISI 4140 steel. High thermal loads can result in specific material modifications, e.g., hardness reduction and tensile residual stresses, due to inappropriate combinations of system and process parameters which influence the functional performance of the ground component in a negative way. In order to avoid this damaging impact due to the thermal effect, an in-depth understanding of the thermal loads and the resulting modifications is required. This relationship is described in the concept of Process Signatures applied in this paper. Experimentally determined temperature-time histories at various depths below the surface were used to estimate the thermal loads at the surface and subsurface using a numerical approach based on the finite element method (FEM). The results show that the hardness change during surface grinding correlates with the maximum temperature rate at given maximum temperatures. In addition, correlations between the hardness change and the Hollomon–Jaffe parameter are identified, taking into account both the absolute temperature and its evolution over time. Furthermore, it was shown that the surface residual stresses correlate with the maximum local temperature gradients at the surface if no detectable tempering of the microstructure takes place.

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Section: Evaluation Of Hardness Changes Due To Thermal Loadssupporting

confidence: 60%

Section: Introduction and State Of The Artmentioning

confidence: 99%

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Evaluation of Hardness and Residual Stress Changes of AISI 4140 Steel Due to Thermal Load during Surface Grinding

Kohls

Heinzel

Eich

2021

JMMP

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“…Large cut-depth grinding includes creep feed grinding [92,100,[167][168][169] and high-efficiency deep grinding (HEDG) [170,171]. HEDG, in particular, is characterized by high wheel speed, high workpiece speed, and large cut depth.…”

Section: Deep Cutting Grindingmentioning

confidence: 99%

Temperature field model in surface grinding: a comparative assessment

Yang,

Kong,

et al. 2023

Int. J. Extrem. Manuf.

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Grinding is a crucial process in machining workpieces because it plays a vital role in achieving the desired precision and surface quality. However, a significant technical challenge in grinding is the potential increase in temperature due to high specific energy, which can lead to surface thermal damage. Therefore, ensuring control over the surface integrity of workpieces during grinding becomes a critical concern. This necessitates the development of temperature field models that consider various parameters, such as workpiece materials, grinding wheels, grinding parameters, cooling methods, and media, to guide industrial production. This study thoroughly analyzes and summarizes grinding temperature field models. First, the theory of the grinding temperature field is investigated, classifying it into traditional models based on a continuous belt heat source and those based on a discrete heat source, depending on whether the heat source is uniform and continuous. Through this examination, a more accurate grinding temperature model that closely aligns with practical grinding conditions is derived. Subsequently, various grinding thermal models are summarized, including models for the heat source distribution, energy distribution proportional coefficient, and convective heat transfer coefficient. Through comprehensive research, the most widely recognized, utilized, and accurate model for each category is identified. The application of these grinding thermal models is reviewed, shedding light on the governing laws that dictate the influence of the heat source distribution, heat distribution, and convective heat transfer in the grinding arc zone on the grinding temperature field. Finally, considering the current issues in the field of grinding temperature, potential future research directions are proposed. The aim of this study is to provide theoretical guidance and technical support for predicting workpiece temperature and improving surface integrity.

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“…Subsequently, metallographic experiments were carried out to further investigate the tooth flanks after grinding burns and to propose solutions to prevent grinding burns. Heinzel et al [ 14 ] analyzed the thermal and depth effects in different grinding processes by means of experiments, using specific grinding power and contact time to characterize a process lower limit for the occurrence of grinding burns with different kinematics. The effect of the grinding process on the microstructure was an important part of the work by Hüsemann et al [ 15 ]; the metallographic results after grinding showed no significant difference between the metallographic organization of the tooth surface after grinding and before grinding at lower spindle power, and a large change in the tooth surface metallography after grinding at higher spindle power.…”

Section: Introductionmentioning

confidence: 99%

Towards Understanding Subsurface Characteristics in Burn Process of Gear Profile Grinding

et al. 2023

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In gear profile grinding, the grinding burn will greatly influence the anti-fatigue performance of gears. However, the influence of microstructure change caused by grinding burn on gear surface integrity is still unclear. In this paper, full-factor experiments of gear profile grinding are conducted and the grinding temperature is measured during the experiments. Furthermore, the tooth surface integrity including microstructure, residual stress, microhardness, and surface morphology is characterized. The relationship between grinding parameters, grinding burns and subsurface layer properties is analyzed by systematical test results. Radial grinding depths of more than 20 μm matched with wheel speeds below 30 m/s will result in severe grinding burns. The effect of grinding burns on the grain state mainly results in the breakdown of high strength martensite and the formation of inhomogeneous secondary tempered sorbite. The recovery and recrystallization of the microstructure of the tooth subsurface layer after grinding burns is the root cause of the substantial reduction in compressive residual stress and nano-hardness. The occurrence of grinding burns is mainly due to the unreasonable matching of process parameters rather than being influenced by a single grinding parameter alone. The risk of burn can be significantly reduced at greater wheel speeds and lower radial grinding depth. This study presents an insight into the mechanism of the effect of gear profile grinding burns on the surface integrity of the tooth flank.

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Comprehensive analysis of the thermal impact and its depth effect in grinding

Cited by 19 publications

References 13 publications

Evaluation of Hardness and Residual Stress Changes of AISI 4140 Steel Due to Thermal Load during Surface Grinding

Evaluation of Hardness and Residual Stress Changes of AISI 4140 Steel Due to Thermal Load during Surface Grinding

Temperature field model in surface grinding: a comparative assessment

Towards Understanding Subsurface Characteristics in Burn Process of Gear Profile Grinding

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