Surface and Material Modifications of Tempered Steel after Precision Grinding with Electroplated Coarse Grained Diamond Wheels

Heinzel, Carsten; Borchers, Florian; Berger, Daniel; Ehle, Lisa

doi:10.1016/j.procir.2016.02.329

Cited by 13 publications

(6 citation statements)

References 7 publications

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“…During the dressing process, all grains are dressed to form the overall morphology of the grinding wheel. The morphological evolution of individual grains is the basis for studying the evolution of the surface morphology of the grinding wheel [30,31]. We compared the surface morphology of the dressed grinding wheel and the undressed grinding wheel and mark the dressed grains on the surface with red circles, and the results are shown in Figure 14.…”

Section: Effect Of Dressing Parameters On Grinding Wheel Surface Morp...mentioning

confidence: 99%

Research on the Grinding Performance of an Electroplated Coarse-Grained Diamond Grinding Wheel by Dressing

Xia,

Deng,

et al. 2024

Machines

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The coarse-grained electroplated diamond grinding wheels is increasingly favored in precision grinding of hard and brittle materials owing to its high material removal efficiency, high wear resistance and steady surface contour accuracy. However, how to determine whether the dressed grinding wheel surface topography can achieve the desired precision ground surface quality is still a huge challenge to this day. In this paper, a novel numerical simulation model, which was established basing on the statistical features of actual electroplated coarse-grained diamond grinding wheel and the kinetics of the grinding process, was proposed for theoretically and thoroughly studying the influence of the surface dressing depth of coarse-grained electroplated diamond grinding wheel on ground workpiece surface morphology. At first, the statistical features of actual electroplated coarse-grained diamond grinding wheel was acquired and a novel numerical grinding wheel surface model was established. Subsequently, a numerical ground workpiece surface simulation model was also developed. And then, the evolving mechanism of the grinding wheel surface topography with the dressed wheel surface abrasive grain protrusion height was theoretically studied by numerical simulation. Moreover, the influence of the wheel surface abrasive grain protrusion height on the ground surface roughness was thoroughly researched by means of theoretical model and experiments. The simulation and experiments results in this paper indicated that precision ground workpiece surface with nano-scale surface roughness can be acquired by grinding with a dressed grinding wheel with a certain abrasive grain protrusion height of 25% of the typical abrasive size. Comparing with the undressed grinding wheel (grinding wheel with original surface topography and not be dressed), the surface roughness Sa and Sq of the surface ground with a well-dressed wheel can achieving a significant decrease of 97.75–99.77% and 97.57–99.73%, respectively. Therefore, carefully dressing the electroplated coarse-grained diamond grinding wheel is of great significance for obtaining a precision ground workpiece surface quality.

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Section: Effect Of Dressing Parameters On Grinding Wheel Surface Morp...mentioning

confidence: 99%

Research on the Grinding Performance of an Electroplated Coarse-Grained Diamond Grinding Wheel by Dressing

Xia,

Deng,

et al. 2024

Machines

View full text Add to dashboard Cite

show abstract

“…Ehle et al published an investigation of surface modifications, determined using an electron microscope, due to deep rolling [14]. Heinzel et al investigated surface modifications which occur due to precision grinding [15]. A comparison of the different results was, despite the use of a common material with uniform heat treatment, a complex undertaking due to different sample geometries and premachining conditions.…”

Section: Surface Integritymentioning

confidence: 99%

“…The mechanical impact, combined with material removal, can result in surface properties such as compressive residual stress depth profiles, which can have positive effects on the surface integrity and, e.g., the wear-resistance of steel workpieces [18]. The mechanical impact can be affected by the process parameters, e.g., low cutting speed v c or the layout of the grinding wheel [15].…”

Section: Grind Strengtheningmentioning

confidence: 99%

Comparison of Different Manufacturing Processes of AISI 4140 Steel with Regard to Surface Modification and Its Influencing Depth

Borchers

Clausen

Eckert

et al. 2020

Metals

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The surface and subsurface conditions of components are significant for their functional properties. Every manufacturing process step changes the surface condition due to its mechanical, chemical and/or thermal impact. The depth of the affected zone varies for different machining operations, and is predetermined by the process parameters and characteristics. Furthermore, the initial state has a decisive influence on the interactions that lead to the final surface conditions. The aim of the investigation presented here is to compare the influence of the load characteristics over the depth applied to manufactured components by several different machining operations and to determine the causing mechanisms. In order to ensure better comparability between the surface modifications caused by different machining operations, the same material was used (AISI 4140; German steel grade 42CrMo4 acc. to DIN EN 10083-3) and annealed to a ferritic-pearlitic microstructure. Based on interdisciplinary cooperation within the collaborative research center CRC/Transregio 136 “Process Signatures”, seven different manufacturing processes, i.e., grinding, turning, deep rolling, laser processing, inductive heat treatment, electrical discharge machining (EDM) and electrochemical machining (ECM), were used, and the resulting surface zones were investigated by highly specialized analysis techniques. This work presents the results of X-ray measurements, hardness measurements and electron microscopic investigations. As a result, the characteristics and depths of the material modifications, as well as their underlying mechanisms and causes, were studied. Mechanisms occurring within 42CrMo4 steel due to thermal, mechanical, chemical or mixed impacts were identified as phase transformation, solidification and strengthening due to dislocation generation and accumulation, continuum dynamic recrystallization and dynamic recovery, as well as chemical reactions.

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“…In a number of published studies, a few solutions have been proposed to improve one or some specific parameters for the grinding process in machining this steel (or equivalents). In a paper [20], a special dressing method to produce flattened coarse grains. The aim of that study was to improve the hardness as well as increase the residual compressive stress on the part surface when grinding AISI 4140 steel.…”

Section: Introductionmentioning

confidence: 99%

Improving the Efficiency of Grinding Process Using the Rubber-Pasted Grinding Wheel

Trung

Hoang

2022

Strojnícky Časopis - Journal of Mechanical Engineering

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This paper studies the efficiency improvement of AISI 4140 steel external cylindrical grinding process. Experiments were carried out with two types of grinding wheels, a conventional and the rubber-pasted grinding wheels. With each type of the wheel, nine experiments were performed. Cooling fluid, spindle speed, feed rate and depth of cut are variables in the experiments. Two outcomes used to evaluate grinding efficiency are surface roughness and material removal rate (MRR). Experimental results demonstrate that the surface roughness achieved in the grinding operation using the rubber-pasted grinding wheels is smaller than using the conventional wheel. The Data Envelopment Analysis-based Ranking (DEAR) method was applied to determine the optimal values of the input parameters for the “minimum” surface roughness and “maximum” MRR in the cases of using each grinding wheel. It is found that the optimization of the input parameters in this circumstance are equal. Several grinding experiments for examining the values of the variables were also performed for both the wheels. The results also confirm that the surface roughness in the grinding process with the rubber wheels is about 19.42% smaller than the conventional wheels.

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Surface and Material Modifications of Tempered Steel after Precision Grinding with Electroplated Coarse Grained Diamond Wheels

Cited by 13 publications

References 7 publications

Research on the Grinding Performance of an Electroplated Coarse-Grained Diamond Grinding Wheel by Dressing

Research on the Grinding Performance of an Electroplated Coarse-Grained Diamond Grinding Wheel by Dressing

Comparison of Different Manufacturing Processes of AISI 4140 Steel with Regard to Surface Modification and Its Influencing Depth

Improving the Efficiency of Grinding Process Using the Rubber-Pasted Grinding Wheel

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