Effect of crystallographic orientation on residual stress induced in micro-grinding

Zhao, Man; Mao, Jian; Ji, Xia; Feng, Yixuan; Liang, Steven Y.

doi:10.1007/s00170-020-06329-z

Cited by 16 publications

(5 citation statements)

References 36 publications

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“…𝜏 𝑤 (𝑥) = 𝜇𝜎 𝑤 (𝑥) 𝑓𝑜𝑟 𝑙 𝑟𝑢𝑏 (1 − √ 𝜏 1 𝜎 1 ) < 𝑥 < 𝑙 𝑟𝑢𝑏 (18) where 𝜏 1 is the shear strength of the friction zone, 𝜇 is the friction coefficient of the friction zone, and 𝑙 𝑟𝑢𝑏 is the length of the scratch, can be expressed as follows: (20) In the grinding process, the cutting edge processed first will make the subsequent smaller cutting edge unable to contact the workpiece, and it is impossible to ensure that all abrasive particles can participate in the machining. According to the motion relationship in the axial ultrasonic vibration-assisted grinding process, the number of dynamic abrasive particles is also affected by ultrasonic vibration.…”

Section: Fig6 Schematic Diagram Of the Three Stages Of Single Grit Gr...mentioning

confidence: 99%

“…The main reasons for the formation of grinding residual stresses are mechanical stresses, thermal stresses and phase transition stresses [15][16][17]. Micro-grinding experiments on aluminum alloy 7075-T6 material by Zhao et al [18] showed that residual compressive stresses occur on the machined surface when the feed rate is below a critical value. Ding et al [19] flowed the flow stresses by taking into account the specific volume and yield stresses in the process of phase transformation to modeling, developed a finite element model to simulate the motion and application of thermo-mechanical loads and the phase transformation on the surface and subsurface of the machined material, and the simulation results showed that the effect of the phase transformation on the residual stresses was mainly on the tangential subsurface.…”

Section: Introductionmentioning

confidence: 99%

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Mechanism and prediction of residual stress generation in ultrasonic vibration-assisted grinding of bearing steel

Zhang,

Luan,

Zhao

et al. 2024

Preprint

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The surface residual stress of the parts has an important influence on their performance. The generation mechanism of surface residual stress in ultrasonic vibration-assisted grinding (UVAG) of bearing steel was investigated, and the correlation between processing parameters and residual stresses was obtained. Based on the ultrasonic vibration-assisted grinding force and thermal model and the flow stress model considering the initial material microstructure, the mechanical and thermal stresses of the material were calculated. Finally, the theoretical model of residual stress is established based on the yield theory and experimentally verified. High-speed ultrasonic aerostatic spindle for ultrasonic vibration-assisted grinding, change the inlet pressure to realize the ultrasonic amplitude and frequency adjustment, the experimental results show that the cutting direction and the vertical cutting direction of the residual stress test results and the model prediction results of the average relative error of 11.4% and 11.7%, and the rule of change is more consistent. Based on the experimental results, the influence pattern of process parameters on the experimental results was analyzed. The results show that the residual compressive stress on the surface of ultrasonic vibration-assisted grinding is directly proportional to the grinding depth, feed rate, and inlet pressure of pneumatic ultrasonic wave, and inversely proportional to the linear speed of the grinding wheel. This study provides a theoretical basis for the analysis of UVAG residual stress and optimization of UVAG process parameters.

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Section: Fig6 Schematic Diagram Of the Three Stages Of Single Grit Gr...mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Mechanism and prediction of residual stress generation in ultrasonic vibration-assisted grinding of bearing steel

Zhang,

Luan,

Zhao

et al. 2024

Preprint

Self Cite

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“…Huang et al [29] proposed an initial condition and its calibration method in stress relaxation, emphasizing the need to determine the initial stress state during the stress relaxation process, and offered an initial condition determination criterion based on surface residual stress calibration. In addition, Zhao et al [30] used the Taylor factor to quantify the crystal orientation of the workpiece material to study the distribution of residual stress in micro-grinding. Research results show that microgrinding can produce more considerable residual compressive stress at lower grinding wheel speeds, smaller Taylor coefficients, and more considerable cutting depths.…”

Section: Introductionmentioning

confidence: 99%

Prediction method for residual stress evolution caused by rolling/sliding contact in ultrasonic vibration-assisted grinding

Ye,

Jun,

Tang

et al. 2024

Preprint

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Ultrasonic vibration-assisted grinding (UVAG) technology has advantages in improving part surface integrity. Currently, the calculation of residual stresses in UVAG typically relies on commercial finite element software. However, because commercial finite element software is not specialized for residual stress calculations, the computational efficiency could be higher, and the accuracy could be better. This paper proposes a semi-analytical residual stress prediction model that considers the Influence of ultrasonic vibration. This paper introduces a semi-analytical residual stress prediction model that considers the impact of ultrasonic vibration. The model calculates the grinding mechanical and thermal stress fields separately using contact mechanics and finite difference methods. Based on Hertz's contact theory and Timoshenko's thermoelastic theory, a correlation model is provided for the association between mechanical and thermal loads with the internal stresses in the workpiece. Subsequently, the residual stress field is solved by considering the thermal-mechanical coupling effects in UVAG. Ultrasonic-assisted grinding experiments were conducted using 12Cr2Ni4A alloy steel as the object, and the maximum error between the predicted residual stresses by the model and the measured residual stresses was 10.5%.In addition, the detailed discussion on the Influence of grinding parameters on residual stress reveals that reducing the grinding wheel speed can significantly increase surface compressive residual stress. The paper's research shows that the residual stress distribution obtained by the new residual stress calculation model is correct, and the calculation efficiency is high, providing a new method for predicting residual stress in UVAG.

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“…Note that in technological processes, the initial material microstructure (crystallite orientation, phase composition, grain size, etc.) plays a decisive role in the manufacturing of parts and significantly affects the properties of the finished product, so it must be taken into account in the models [9,10]. In accordance with an accepted hypothesis about the relationship between the variables (characteristics) of different levels (a means of combining the elements of the underlying scale level into an element of the overlying scale level), crystal plasticity CMs are divided into three main groups: statistical [11], self-consistent and direct (the latter are based on the solution of a boundary value problem at the level of grain parts) [12] models.…”

Section: Introductionmentioning

confidence: 99%

Advanced Statistical Crystal Plasticity Model: Description of Copper Grain Structure Refinement during Equal Channel Angular Pressing

Romanov

Shveykin

Трусов

2023

Metals

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The grain structure of metals changes significantly during severe plastic deformation (SPD), and grain refinement is the main process associated with SPD at low homologous temperatures. Products made of ultrafine-grained materials exhibit improved performance characteristics and are of considerable industrial interest, which generates a need for the creation of comprehensive grain refinement models. This paper considers the integration of the ETMB (Y. Estrin, L.S. Toth, A. Molinari, Y. Brechet) model, which describes the evolution of an average cell size during deformation into the two-level statistical crystal plasticity constitutive model (CM) of FCC polycrystals. The original relations of the ETMB model and some of its modifications known from the literature were analyzed to obtain an accurate, physically admissible description of the grain refinement process. The characteristics of the grain substructure determined with the framework of the advanced ETMB model were taken into account in the CM in a hardening formula. By applying the CM with the integrated ETMB model, numerical experiments were performed to simulate the changes in the grain structure of copper during equal channel angular pressing (ECAP) at room temperature. The results obtained are in good agreement with the experimental data. The ideas about further development of the proposed model are outlined.

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Effect of crystallographic orientation on residual stress induced in micro-grinding

Cited by 16 publications

References 36 publications

Mechanism and prediction of residual stress generation in ultrasonic vibration-assisted grinding of bearing steel

Mechanism and prediction of residual stress generation in ultrasonic vibration-assisted grinding of bearing steel

Prediction method for residual stress evolution caused by rolling/sliding contact in ultrasonic vibration-assisted grinding

Advanced Statistical Crystal Plasticity Model: Description of Copper Grain Structure Refinement during Equal Channel Angular Pressing

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