Thermo-mechanical coupling effect on surface residual stress during ultrasonic vibration-assisted forming grinding gear

Zhao, Bo; Guo, Xingchen; Bie, Wenbo; Chang, Baoqi; Zhao, Cuihua

doi:10.1016/j.jmapro.2020.09.041

Cited by 60 publications

(21 citation statements)

References 10 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…At relatively low grinding speed, the compressive residual stress decreased with the increase of grinding depth [6]. Compressive residual stress reduced from 350 MPa to 200 MPa when grinding speed increased from 2000 min À 1 to 6000 min À 1 [7].…”

Section: Introductionmentioning

confidence: 93%

Residual stress evolution and surface morphology in grinding of hardened steel following carburizing and quenching processes

Yang¹,

Chen²,

Wu³

et al. 2022

Materialwissenschaft Werkst

View full text Add to dashboard Cite

In this paper, the residual stress evolution and surface morphology of quenched 20Cr2Ni4A steel after surface grinding with alumina grinding wheel was investigated. The initial compressive residual stress in the surface layer evolved into tensile stress after grinding. Since thermal stress was the dominated factor, the effect of grinding speed and grinding depth showed significant effects on the level of residual stress. The tensile stress on the ground surface increased by more than 50 % when grinding speed increased from 26 m/s to 34 m/s at the feed speed of 0.19 m/s to 0.26 m/s. The increase of grinding depth from 0.02 mm to 0.03 mm resulted in the increase rate of tensile stress varying between 54 % and 85 % at specific feed speed and grinding speed. Due to the extrusion and cutting of abrasive particles, plastic deformation and grooves were found on the machined surface. The influence of grinding heat and grinding force caused a plastic deformation layer and grinding burn layer within 20 μm.

show abstract

Section: Introductionmentioning

confidence: 93%

Residual stress evolution and surface morphology in grinding of hardened steel following carburizing and quenching processes

Yang¹,

Chen²,

Wu³

et al. 2022

Materialwissenschaft Werkst

View full text Add to dashboard Cite

show abstract

“…58 Vibration assisted forming grinding gear (VAFGG) a novel process had been proposed by researchers in which it had been reported that with ultrasonic vibration assistance the force required to grind the gear shape was reduced by 40%. 59 Various research studies have reported that the micro upsetting process may also be combined with an ultrasonic vibration setup for decreasing the flow stress of the material. The study also observed that flow stress of metal may also be decreased by reducing the size of the component as well as increasing the grain size of alloy.…”

Section: Vibration Assistance Formingmentioning

confidence: 99%

An insight into ultrasonic vibration assisted conventional manufacturing processes: A comprehensive review

Kumar¹,

Kumar²,

Singh³

et al. 2022

Advances in Mechanical Engineering

View full text Add to dashboard Cite

Conventional manufacturing processes such as casting, forming, welding, machining, etc., have been optimized using different improvement techniques in the last few decades. The alterations in these processes have led to more efficient and productive manufacturing practices for the industry. One of these modification techniques is the deployment of ultrasonic vibrations in conventional manufacturing processes. In the last few decades, ultrasonic vibration assistance to manufacturing processes has seen an uprise and was the point of attraction for different research groups. Several improvements by utilizing ultrasonic vibration in manufacturing practices have been reported by the authors in the past. In this article, an attempt has been made to review all the reported techniques for different conventional processes viz. casting, forming, machining, and welding. The article outlines different research findings from the extensive work on ultrasonic vibration assistance showcasing the improved mechanical and morphological properties. The improvisation in the performance parameters viz. friction reduction, stress reduction, tool wear, surface finish, and grain structure has been witnessed by ultrasonic assistance in contrast to simple manufacturing processes. The outcomes have been summarized along with the optimized set of parameters from various studies.

show abstract

“…Zhao et al 79 proposed the ultrasonic vibration-assisted forming grinding gear, and investigated the thermo-mechanical coupling effect on surface residual stress. It was found that the surface residual compressive stress gradually decreases with the increase in spindle speed, while it increases first and then decrease with the increase in ultrasonic amplitude.…”

Section: Review On Ultrasonic Compound Machining Of Gearsmentioning

confidence: 99%

Ultrasonic assisted machining of gears with enhanced fatigue resistance: A comprehensive review

Bie

Zhao

et al. 2022

Advances in Mechanical Engineering

Self Cite

View full text Add to dashboard Cite

In recent years, ultrasonic-assisted machining (UAM) has been widely implemented to improve the performance and element quality of machined products. This paper comprehensively reviews the ultrasonic vibration effects on such ultrasonic vibration-assisted (UVA) processes as hobbing (UVAH), lapping (UVAL), electrochemical gear machining (UVAEGM), honing (UVAH), and grinding (UVAG), respectively. Compared with the conventional machining, the UAM significantly reduced the surface roughness, improved the surface microstructure, and quality. Considering the UAM applications surface modification and surface strengthening, the available technologies of ultrasonic impact, ultrasonic shot peening, and ultrasonic deep rolling were analyzed for gears and similar components. It was concluded that the surface was strengthened under UAM through introducing the high-amplitude and large-depth residual compressive stresses, restraining crack propagation to a certain extent, and improving the gear fatigue resistance. Finally, the ultrasonic machining effect on gear fatigue resistance was theoretically substantiated from the ultrasonic vibration system and surface integrity standpoints. This review aims to optimize the application of ultrasonic-assisted machining, in order to produce gears with enhanced fatigue resistance and surface integrity.

show abstract

Thermo-mechanical coupling effect on surface residual stress during ultrasonic vibration-assisted forming grinding gear

Cited by 60 publications

References 10 publications

Residual stress evolution and surface morphology in grinding of hardened steel following carburizing and quenching processes

Residual stress evolution and surface morphology in grinding of hardened steel following carburizing and quenching processes

An insight into ultrasonic vibration assisted conventional manufacturing processes: A comprehensive review

Ultrasonic assisted machining of gears with enhanced fatigue resistance: A comprehensive review

Contact Info

Product

Resources

About