Prediction on residual stress with mechanical-thermal and transformation coupled in DGH

• Published in: International journal of mechanical sciences 2020-08, Vol.179, p.105629, Article 105629
• Main Authors: Sun, Cong, Xiu, Shichao, Hong, Yuan, Kong, xiangna, Lu, Yue
• Format: Article
• Language: English
• Subjects: Consistency; Depth of cut; Dynamic characteristics; Grinding hardening; Residual stress
• ISSN: 0020-7403
• DOI: 10.1016/j.ijmecsci.2020.105629

•A novel prediction model for the ground workpiece's residual stress is established in DGH.•The system dynamic, the metallurgical transformation behavior and the mechanical-thermal interaction are all considered integrally.•An in-depth effective mechanism for residual stress in DGH is conducted in different depth of cut.•The consistency of workpiece's residual stress is further validated by the DGH experiments. The grinding hardening has played a major role in surface machining process combined with the mechanical engineering and the metallurgical behavior. Notably, the machining process is with system's dynamic, and a large amount of plastic deformations generate in the dynamic grinding hardening (DGH) process, which results in residual stress on the workpiece surface layers. To this end, the paper presents a novel model on predicting the residual stress considering the dynamic characteristic, the mechanical-thermal interaction and the transformation effect integrally. In this model, the analytic modeling on the mechanical-thermal coupling is established and treated as the input of the transformation firstly. Afterwards, the content of the hardening layers is calculated by the cellular automata (CA). Finally, the multi-phase field residual stress is established on the above factors, the results of which goes well with the DGH experiments. It shows that the consistency of the residual stress distribution varies a lot with the grinding position and the depth of cut. By comparison, the larger depth of cut at the stable grinding zone can bring about the compressive residual stress. This approach can enhance the recognization of formation mechanism of the DGH residual stress, and importantly can be a reference in optimizing the residual stress for manufacturing process. [Display omitted]