Study on the influence of the grinding chatter on the workpiece’s microstructure transformation

Sun, Cong; Liu, Zhenxin; Lan, Dongxue; Duan, Jinchao; Xiu, Shichao

doi:10.1007/s00170-018-1794-3

Cited by 19 publications

(6 citation statements)

References 38 publications

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“…Chatter vibration is induced by regenerative force, and a chatter-free grinding process is always required to ensure high surface quality [5]. It is necessary to predict the chatterfree regions in the physical parameter space.…”

Section: A Continuation Algorithm For Chatter Boundariesmentioning

confidence: 99%

“…Internally excited vibration, also called regenerative chatter, is induced by the regenerative effects on the surfaces of both the workpiece and the grinding wheel [4], which result from certain physical parameters of the grinding system. Since regenerative chatter vibration always induces poor surface quality [5], it is necessary to study the relationship between the dynamical behaviors and the physical parameters of the grinding system in order to eliminate such vibrations.…”

Section: Introductionmentioning

confidence: 99%

“…It has been realized that the occurrence of grinding chatter is a kind of doubly regenerative vibration [5,6]. Unlike the turning [7,8] or milling [9,10] processes, which involve a single time delay from the regeneration of the workpiece, the dynamic behavior of the grinding process is affected by two distinct time delays induced by the regenerative effects on the surfaces of both the workpiece and the wheel.…”

Section: Introductionmentioning

confidence: 99%

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Stability Analysis and Nonlinear Chatter Prediction for Grinding a Slender Cylindrical Part

Sun

Yan

2023

Processes

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A cylindrical plunge grinding process was modeled to investigate nonlinear regenerative chatter vibration. The rotating workpiece was a slender Euler–Bernoulli beam, and the grinding wheel was a rigid body moving towards the workpiece at a very low feed speed. A numerical method was proposed to provide the critical boundaries for chatter-free grinding. It was demonstrated that the intersection set surrounded by these critical boundaries was the chatter-free region for the considered parameters. When these parameters were outside of the chatter-free region, the stable grinding process underwent a supercritical Hopf bifurcation, resulting in the loss of the chatter-free behavior and the emergence of periodic chatter motions. Then, the periodic motions of both the grinding wheel and the workpiece were predicted analytically using the method of multiple scales, showing the effect of the regenerative force on the grinding process. We demonstrated that the analytical prediction was valid since it agreed with the numerical simulation. The results showed that there exist three kinds of nonlinear chatter motion, with different amplitudes and mode frequencies.

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Section: A Continuation Algorithm For Chatter Boundariesmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Stability Analysis and Nonlinear Chatter Prediction for Grinding a Slender Cylindrical Part

Sun

Yan

2023

Processes

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“…The microstructure before and after grinding was observed by transmission electron microscope (TEM), and it was found that the original boundaries of ferrite and martensite phases became blurred and some dislocations appeared in the structure. Although the research object is not gears, there are many excellent studies on grinding microstructure evolution by Xiu and Sun et al For example, the effect of grinding chatter on martensite nucleation and growth and the mechanism of grain refinement in the grinding metamorphic layer were investigated by combining the calculation of the grinding temperature field with a hybrid model of metamorphic automata [ 20 , 21 ]. A digital twin model was proposed to study the evolution of grinding temperature and microstructure along the surface depth direction from a microscopic perspective [ 22 ].…”

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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“…Under certain parameters, the stability of the system is destroyed, and chatter occurs. The phenomenon of chatter generated from the machining process is a self-exited vibration between the cutting tool and workpiece [2][3][4], which results in poor surface quality and dimensional accuracy of the workpiece and accelerates the abrasion of the tool [5][6][7][8][9]. Generally, as the final procedure of machining, grinding has significance for the quality of the workpiece [10][11][12].…”

Section: Introductionmentioning

confidence: 99%

Theoretical and Experimental Analysis of Grinding Stability of Beam Workpiece

Yao

2023

Processes

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Grinding chatter is a kind of self-excited vibration in which the grinding system continuously absorbs energy from the grinding machine, increasing the mechanical energy of the system. Grinding chatter can damage the surface of the workpiece and accelerate the abrasion of the grinding wheel. The theoretical analysis of the grinding chatter for the beam surface was launched based on the behavior of a single abrasive grain, whose cutting thickness is a key factor affecting grinding stability. The dynamic grinding force model has been developed, which is the interaction interface between the grinding wheel and the workpiece. In this paper, rail beam grinding was taken as an example. The vibration performance of the rail beam was described with the Timoshenko beam. The characteristics of the frequency domain of the grinding wheel-workpiece system were observed, and the condition of the stability at any position in the longitudinal direction of the beam was gained, which could be quantitatively characterized with the stability limit curve. The grinding experiments of the rail beam surface demonstrated that as chatter developed, the chatter marks could be investigated on the surface of the rail, and the energy of the chatter signal was mainly concentrated around the chatter frequency, which was higher than the natural frequency of the grinding wheel.

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Study on the influence of the grinding chatter on the workpiece’s microstructure transformation

Cited by 19 publications

References 38 publications

Stability Analysis and Nonlinear Chatter Prediction for Grinding a Slender Cylindrical Part

Stability Analysis and Nonlinear Chatter Prediction for Grinding a Slender Cylindrical Part

Towards Understanding Subsurface Characteristics in Burn Process of Gear Profile Grinding

Theoretical and Experimental Analysis of Grinding Stability of Beam Workpiece

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