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Procedia CIRP 14 (2014) 2 – 6
Abstract
Residual stress is a key factor that influences the reliability, precision, and life of final products. Earlier studies have alluded to the fact that the
grinding process is usually the source of a tensile residual stress on the part surface, while there exists a temperature level commonly referred to
as the onset tensile temperature beyond which the tensile profile of residual stresses starts to be generated. In this paper, a physics-based model
is proposed to predict the onset temperature as a function of residual stress on an analytical and quantitative basis. The predictive model is
based on the temperature distribution function using a moving heat source approach. Then, the thermal stresses are calculated analytically using
Timoshenko thermal stress theory [1] followed by an elastic-plastic relaxation condition imposed on these stresses, thus leading to the resulting
residual stresses. The model-predicted results have been experimentally validated using data of the grinding of AISI52100 hardened steel with
subsequent X-ray and Neutron diffraction measurements. The model was shown to predict the residual stress profile under given process
conditions and material properties, therefore providing an analytical tool for grinding process planning and optimization based on the
understanding of onset tensile temperature for control of tensile residual stresses.
© 2014 Elsevier B.V. This is an open access article under the CC BY-NC-ND license
© 2014 The Authors. Published by Elsevier B.V.
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection and peer-review under responsibility of the International Scientific Committee of the 6th CIRP International Conference on High
Selection andCutting.
Performance peer-review under responsibility of the International Scientific Committee of the 6th CIRP International Conference
on High Performance Cutting
Keywords: Grinding, Tensile, Residual Stress, Onset Temperature
2212-8271 © 2014 Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection and peer-review under responsibility of the International Scientific Committee of the 6th CIRP International Conference
on High Performance Cutting
doi:10.1016/j.procir.2014.03.100
Omar Fergani et al. / Procedia CIRP 14 (2014) 2 – 6 3
where
P
q0 (2)
lc b
lc
ª 1/2 ½
vw x x ' z 2 º °
2
2 vw ( x x ') °
qRw ° ¬« ¼» ° dx '
T( x , z )
³
l
Sk
e 2D K 0®
° 2D
¾
°
(3)
c
2
°
¯ °
¿
f f
DE § wT wT
therm
V xz
³ ³ ¨© G xzh x ', z ' Gxzv x ', z ' ·¸ dx ' dz '
1 2Q wx wz ¹
0 f
(6)
2 f
2z p(t )(t x )
S ³ (t x )
f
2
z2
dt
Omar Fergani et al. / Procedia CIRP 14 (2014) 2 – 6 5
(V zz )r (W xz )r (H xx )r
where 'V zz 'W xz 'H xx (14)
M M M
D ET ( x, z 0) where M is the number of increments taken in the
p(t ) (7)
1 2Q relaxation process. During relaxation, there are two kinds of
material behavior: purely elastic relaxation and elastic-plastic
and ሺ
୶୦ ,
୶୴ ,
୶୦ ,
୦ ,
୶୦ ,
୶୴ ሻ are the plain strain relaxation
Green’s functions as can be found in the literature [10].
3. Results and validation
V therm
yy Q therm
V xx therm
V zz (8)
The proposed model was validated by the experimental
results obtained by [4]. The same cutting conditions and
Using the stress field calculated above, the residual stresses materials systems were implemented in both model-prediction
are computed from assuming a rolling/sliding contact case, as and experimentation. Grinding was carried out on one side of
proposed by McDowell [11]. each sample on an Abwood HS5025CP grinding machine. An
The hybrid model uses a blending function Ȳ which is aluminum oxide wheel was used. Three wheel speeds (= ܛܞ
dependent on the instantaneous value of the modulus ratioȀ 20, 30 and 40ms−1) and three workpiece speed ( = ܟܞ0.1,
. Herein
is the elastic shear modulus, the modulus 0.2 and 0.3ms−1) were used. Depths of cut were in
function and Ɉ an algorithm constant. The blending function is the range 0.53–10.63 μm. Tables 1 and 2 present the material
given as: physical properties and Johnson-Cook flow stress model
coefficients that were used in the computational
§ 3h·
(9) implementation from [12].
< 1 exp ¨ N ¸
© 2G¹
Table.1 Material Properties for AISI 52100
Therefore the residual strain in both direction under the plane E (GPa) ߥ ܥ ሺ
ݐܭ ρ α (um/m- ܶ (C)
strain conditions can be calculated as: Ȁ W/m- (kg/m3) C)
െ ሻ C
1
H xx ªV xx Q V yy V zz* º D'T
E¬ ¼ ʹͲͲ 0.28 475 46.6 7833 ͳͳିͲͳݔ 1480
1
h
V xx nxx V yy n yy V zz* nzz 2W xz* nxz nxx
(10) Table.2 Johnson-Cook coefficients for AISI 52100
1 * A ܤ ܥ ݉ n D ܧ
< ( ª¬V xx Q V yy V zz* º¼ D'T
E 1712 408 0.0211 1.21 0.391 1 1
1 *
h
V xx nxx V yy n yy V zz* nzz 2W xz* nxz nxx )
The grinding force and power were calculated based on the
grinding parameters and the heat partition into the workpiece
1
H yy ªV yy Q V xx V zz* º D'T was calibrated using the maximum grinding zone temperature.
E¬ ¼ (11) Figure 4 and 5 shows the obtained results. The curves are
1
h
V xxnxx V yy n yy V zz* nzz 2W xz* nxz n yy 0 plotted for the surface of the workpiece.
the loading passage the residual stresses can be determined. 600 sim_grinding direction
Besides, the following boundary conditions are given by 500
Merwin and Johnson: 400
300
(H xx ) r (H yy ) r (J xy ) r (J yz ) r 0 200
(12)
(V xx ) r f1 ( z ) (V yy ) r f2 ( z) 100
0
(V zz ) r (W xz ) r (W xy ) r (W yz ) r 0 -100 0 100 200 300 400
(13) Temperature °C
(H zz ) r f3 ( z) (J xz ) r f 4 ( z)
Fig.4 Residual stress vs. temperature in grinding direction on the surface
In order to retain equilibrium, any non-zero
components ሺɐ ሻ୰ , ሺɒ୶ ሻ୰ , ሺɂ୶୶ ሻ୰ are incrementally relaxed
until the boundary conditions are met.
6 Omar Fergani et al. / Procedia CIRP 14 (2014) 2 – 6
500
exp_traverse direction This paper presented the new development of a prediction
Residual Stress (MPa) 400 model of the onset temperature responsible for the activation
300 sim_traverse direction of the tensile residual stress on a grinded part surface. This
model is based on a physics-based understanding of the
200
elastic-plastic stresses and strains generated by a non-uniform
100 heating operation in grinding. An approach based on three
steps was pursued: The temperature generated by the grinding
0
process was first predicted; then the thermal stresses
0 100 200 300 40
-100 composed of the body forces, surface traction and hydrostatic
pressure were calculated analytically; then an elastic plastic
-200
relaxation procedure was applied to meet the stain
-300 Temperature °C compatibilities. The residual stress profile was expressed as a
function of temperature, thus related to process parameters
and material properties. The model-based simulations were
Fig..5 Residual stress vs. temperature in transverse direction on the surface experimentally validated in the case of AISI 52100 grinding
for which the onset temperature was found to be around
As shown in Figures 4 and 5, it can be observed that the ૢ for both cutting and transverse directions. The model-
onset temperature for the hardened steel AISI 52100 was experimental comparison further justifies the assumption that
around ୭୬ୱୣ୲ ൌ ͳͻͲ for both traverse and cutting mechanical stress has a limited effect on tensile residual stress
directions. Above this grinding temperature, the residual generation. The results of this new study could provide a
stresses predicted and measure on the workpiece surface are scientific basis for planning of grinding configuration and
tensile The proposed model in this paper uses a new physics- parameters in the interest of residual stress control.
based approach to predict residual stress generation as a
function of grinding temperature with accuracy especially for References
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