Grinding burn inspection – tools for supervising and  objectifying of the testing process

Seidel, Martin W.; Zösch, Antje; Härtel, Konstantin

doi:10.51202/9783181022948-1003

Cited by 4 publications

(6 citation statements)

References 2 publications

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“…The results of hardness and magnetic Barkhausen noise measurements in the trans verse direction to the laser-beam movement suggested the existence of a correlation be tween the hardness and BN signal intensity. It was found that the inverse of the MBN (1/MBN) value was directly proportional to the hardness value on the surface of the trac As mentioned in [27], specific and reproducible grinding burns are difficult to generate. Therefore, the artificial defects must be generated in controlled manner.…”

Section: Discussionmentioning

confidence: 99%

“…The higher content of retained austenite in track 3 (57.5%) compared to track 2 (18.1%) also was likely to affect the RMS value. As mentioned in [27], specific and reproducible grinding burns are difficult to gen erate. Therefore, the artificial defects must be generated in controlled manner.…”

Section: Magnetic Barkhausen Noise Analysismentioning

confidence: 99%

“…Several non-destructive testing (NDT) techniques are used in quality control of carburized case-hardened gears, such as Barkhausen noise analysis, micromagnetic multiparameter microstructure and stress analysis, eddy current signal, and recently digital image processing [4,15,16,20,[25][26][27][28]. The magnetic Barkhausen noise (MBN) technique is presently widely and successfully used as an alternative to chemical etching.…”

Section: Introductionmentioning

confidence: 99%

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Evaluation of Thermal Damage Impact on Microstructure and Properties of Carburized AISI 9310 Gear Steel Grade by Destructive and Non-Destructive Testing Methods

et al. 2021

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Advanced aircraft gearboxes operate under high mechanical loads. Currently, aircraft gears are manufactured from chromium–nickel–molybdenum steel grades such as AISI 9310 or Pyrowear 53. The major causes of gear failure are wear and fatigue cracking. As the crack initiation occurs predominantly on the component surface, the gears are routinely subjected to surface hardening processes such as low-pressure carburizing and case hardening. The gears are manufactured in a multiple operation process, in which teeth grinding is a crucial step. Selection of improper grinding conditions can lead to local heat concentration and creation of grinding burns, which are small areas where microstructure and properties changes are induced by high temperature generated during grinding. Their presence can lead to significant reduction of gear durability. Therefore destructive and non-destructive (NDT) quality-control methods such as chemical etching or magnetic Barkhausen noise (MBN) measurements are applied to detect the grinding burns. In the area of a grinding burn, effects related to the over-tempering or re-hardening of the carburized case may occur. In this paper, the results of the studies on the characterization of microstructure changes caused by local heating performed to simulate grinding burns are presented. The areas with the over-tempering and re-hardening effects typical for grinding burns were formed by laser surface heating of carburized AISI 9310 steel. Analyses of the microstructure, residual stresses, retained austenite content, and non-destructive testing by the MBN method were performed. The correlation between the MBN value and the properties of the modified surface layer was identified. It was also found that the re-hardened areas had similar characteristics of changes in the Barkhausen noise intensity, despite the significant differences in the width of the overheated zone, which depended on the laser-heating process conditions.

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Section: Discussionmentioning

confidence: 99%

Section: Magnetic Barkhausen Noise Analysismentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Evaluation of Thermal Damage Impact on Microstructure and Properties of Carburized AISI 9310 Gear Steel Grade by Destructive and Non-Destructive Testing Methods

et al. 2021

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“…Barkhausen noise analysis influence of human factors can be avoided, nondestructive, result is reproducibility. complex relationship between surface integrity of grinding burns and signals of Barkhausen noise analyzer, require calibration blocks for accurate detection, almost impossible to develop grinding burn with defined characteristics on bearing components in a repeatable way [30].…”

Section: Metallographic Examinationmentioning

confidence: 99%

Detection methods and bearing failure characteristics analysis related to grinding burns

Hou,

Liu,

Liu

et al. 2024

J. Phys.: Conf. Ser.

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Grinding burn is one of the bearing failure causes for components. In order to quickly confirm that grinding burn is the cause of bearing failure, detection methods for the grinding burns and characteristics of bearing failure caused by grinding burns have been studied in this paper. The results show that cold acid pickling examination, microhardness test and Barkhausen noise analysis can be used in the detection of heavy grinding burns but have several disadvantages to hinder their application on the detection of slight grinding burns. A grinding burn detection procedure is recommended for the analysis of bearing failure induced by grinding burn. It has been found that the modes of bearing failure induced by grinding burns were contact fatigue spalling developed from the contact fatigue crack, the propagation mechanism of the contact fatigue crack was obtained. And the unique phenomenon of fracture or fragmentation with cracks distributed in the origin or surrounding the spalling pit of the grinding burn layer was also obtained. Based on the above results the future work on detection methods and influence on bearing failure mechanism and life of grinding burn are proposed.

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“…Considering the grinding of hardened steels, the development of high temperatures at the contact zone due to the elevated heat generation can induce thermal damages to the workpiece, such as phase transformations, micro-cracks, tempering, re-hardened, and tensile residual stresses. 5,6 According to Seidel et al, 5 the local overheat in the workpiece during mechanical processing of hardened steel can lead to a tempered zone of the martensite microstructure, which results in hardness reduction. According to Malkin and Guo, 6 the hardness reduction near machined surface is a phenomenon typically found in hardened steel subjected to grinding with conventional abrasive wheels such as alumina.…”

Section: Introductionmentioning

confidence: 99%

Contribution to the selection of cutting fluid type and its application technique for grinding of bearing steel

Paiva

Ruzzi

Silva

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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The elevated heat generation in grinding can develop high temperatures at the contact zone, which can adversely affect the surface integrity of the workpiece, especially when grinding hardened steels with conventional abrasives. Thus, the correct selection of cooling-lubrication condition is essential to avoid or attenuate any possible negative effect to workpiece surface integrity. However, the literature lacks work comparing different cutting fluid application technique (e.g. flood and minimum quantity lubrication – MQL) using the same fluid on both techniques. In this context, this work aims to contribute to the selection of cutting fluid type and its application technique for the grinding of bearing steel. Experimental trials were conducted comparing the use of semisynthetic and synthetic cutting fluids, both applied via conventional (flood) and MQL techniques. Different cutting conditions were also tested. A 24 full factorial design of experiment (DOE) was carried out with the following factors: fluid application technique, type of fluid, workspeed, and radial depth of cut. An analysis of main effects and interactions was performed for surface finish (Ra parameter) results, including a prediction model based on the analysis of variance (ANOVA). The morphology of ground surface and microhardness below machined surface were also analyzed. The results showed that the ground surface finish was strongly dependent on the cutting fluid type and its application technique combination: superior finishing was observed with the combination of semisynthetic fluid delivered via flood technique and with synthetic fluid delivered via MQL technique. From the surface morphology analysis, it was observed that the inferior lubrication capacity of synthetic fluid applied via flood condition deteriorated the surface finish and morphology. The surfaces ground with semisynthetic fluid provided, in general, lower values of Ra and lower microhardness variation. The prediction model for Ra showed a maximum error of 14% in comparison to the measured values.

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Grinding burn inspection – tools for supervising and objectifying of the testing process

Cited by 4 publications

References 2 publications

Evaluation of Thermal Damage Impact on Microstructure and Properties of Carburized AISI 9310 Gear Steel Grade by Destructive and Non-Destructive Testing Methods

Evaluation of Thermal Damage Impact on Microstructure and Properties of Carburized AISI 9310 Gear Steel Grade by Destructive and Non-Destructive Testing Methods

Detection methods and bearing failure characteristics analysis related to grinding burns

Contribution to the selection of cutting fluid type and its application technique for grinding of bearing steel

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