Surface layer modification charts for gear grinding

Jermolajev, Štěpán; Brinksmeier, E.; Heinzel, Carsten

doi:10.1016/j.cirp.2018.04.071

Cited by 19 publications

(3 citation statements)

References 7 publications

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“…Figure 10 shows that the simulated temperature, which experimentally generates thermal damage is in the range of 560-780 • C whilst in general a higher temperature is required to damage the workpiece at higher values of aggressiveness. This result is what might be expected for a given set of removal rate conditions, where greater aggressiveness means a higher rotation speed of the workpiece and thus, less contact time, which reduces the risk of damage [10,12].…”

Section: Influence Of Process Kinematicssupporting

confidence: 66%

Detailed Thermo-Kinematic Analysis of Face Grinding Operations with Straight Wheels

Urgoiti

Barrenetxea

Sánchez³

et al. 2020

Metals

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This paper presents a new model that relates thermal aspects with process kinematics in face grinding applications with straight wheels. Changes in chip thickness along the contact area were considered in the model, which allows for taking into account local thermal effects. The model was validated through grinding tests conducted with conventional alumina wheels. Power signals were used as input for the model. Thermal damage on the ground surface was detected using eddy current technology and revealed by acid etching. Both the model and experimental findings provide the basis for developing an approach for process optimization.

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Section: Influence Of Process Kinematicssupporting

confidence: 66%

Detailed Thermo-Kinematic Analysis of Face Grinding Operations with Straight Wheels

Urgoiti

Barrenetxea

Sánchez³

et al. 2020

Metals

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“…In this context, T denotes the absolute temperature of the tempering process, C is a constant characteristic of the tempered steel, and t is the tempering time. For grinding, this parameter was used to estimate changes at the surface and subsurface [32]. However, the estimation of the annealing time is usually difficult.…”

Section: Evaluation Of Hardness Changes Due To Thermal Loadsmentioning

confidence: 99%

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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“…Jamshidi et al [ 5 ] defined surface burn as a chemical reaction between oxygen and workpiece material and proposed a burn model that comprehensively considered maximum temperature and exposure time to predict oxide layer thickness. Jermolajev et al [ 12 ] established a time–temperature diagram showing surface layer modification for profile gear grinding based on local contact zone temperature measurements and used the tempering time to explain workpiece surface burn rather than contact time, as the grinding temperature could not drop below the tempering temperature instantaneously when the grinding wheel moved away.…”

Section: Introductionmentioning

confidence: 99%

Grinding Temperature and Surface Integrity of Quenched Automotive Transmission Gear during the Form Grinding Process

Jiang

Liu²,

Yan

et al. 2022

Materials

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Grinding burn is an undesired defect in gear machining, and a white layer is an indication of severe burn that is detrimental to gear surface performance. In this work, the influence of grinding parameters on the thickness of the white layer during form grinding of quenched transmission gear was investigated, and the microstructure evolution and mechanism of severe burn formation were analyzed. The grinding temperature increased with the grinding depth and grinding speed, with the highest level of ~290 °C. The thickness of the white layer exceeded 100 μm when the grinding depth was 0.03 mm, and the top layer was a plastic deformation layer followed by a fine-grained martensite layer. Coarse-grained acicular martensite was found at the interface between the white layer and softened dark layer. The mechanical effect and thermal softening mainly contributed to the formation of white layer stratification. The ground surface topography showed several scratches and typical grooves; when grinding depth increased to 0.03 mm, the grinding surface roughness Sa was relatively high and reached up to ~0.60 μm, mainly owing to severe plastic deformation under grinding wheel extrusion and the thermal effect.

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Surface layer modification charts for gear grinding

Cited by 19 publications

References 7 publications

Detailed Thermo-Kinematic Analysis of Face Grinding Operations with Straight Wheels

Detailed Thermo-Kinematic Analysis of Face Grinding Operations with Straight Wheels

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

Grinding Temperature and Surface Integrity of Quenched Automotive Transmission Gear during the Form Grinding Process

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