Residual stress generation in grinding: Mechanism and modeling

Gong, Peng; Zhang, Yanbin; Wang, Chunjin; Cui, Xin; Li, Runze; Sharma, Shubham; Liu, Mingzheng; Gao, Teng; Zhou, Zongming; Wang, Xiaoming; Dambatta, Yusuf Suleiman; Li, Changhe

doi:10.1016/j.jmatprotec.2023.118262

Cited by 17 publications

(2 citation statements)

References 131 publications

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“…The observation that the residuals demonstrate a random distribution within the range of −2 to +2 nearly provides evidence in favour of the proposition that the experimental design and models employed are appropriate for attaining the objective of optimisation. The findings indicate that the models have the potential to be utilised in determining the most optimalamalgamation combination of factor-levels that result in a significant reduction in surface roughness (Garg et al, 2022;Sharma and Sudhakara, 2019;Gong et al, 2023).…”

Section: Mathematical Modelling and Regression Analysismentioning

confidence: 99%

Optimization of surface roughness in milling of EN 24 steel with WC-Coated inserts using response surface methodology: analysis using surface integrity microstructural characterizations

Patil,

Sathish,

Rao

et al. 2024

Front. Mater.

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Introduction: Among alloys of medium-carbon and high-strength steel, EN 24 steel is characterised by its nickel-chromium-molybdenum composition. EN 24 steel is highly suitable for application in heavy-duty projects due to its notable resilience to damage, especially when exposed to low temperatures. With the objective of minimising surface irregularities, this research endeavours to enhance the milling process of EN 24 steel by employing coated tungsten carbide (WC) tool inserts.Methods: Feed rate, cutting speed, depth of cut, and cutting fluid are all crucial process factors in the experimental investigation. Four distinct levels are applied to each factor. The research utilises the Design of Experiments (DOE)-based Central Composite Design of Response Surface Methodology. To predict output parameters, mathematical models are developed utilising analysis of variance (ANOVA) for optimisation purposes.Results and discussions: Through the utilisation of multi-objective optimisation, the optimal combination for tungsten carbide inserts was determined, which provided surface irregularities of 0.301 µm. Cutting speed (CS) of 149.507 m/min, feed rate (FR) of 340.27 mm/min, depth of cut (DOC) of 0.599 mm, and cutting fluid (CF) of 12.50 L/min are the optimal parameters. The surface morphologies of the machined workpiece at particular parameter values can be discerned through scanning electron microscope (SEM) analysis, yielding significant insights. The optimal parameters that have been identified provide practical recommendations for improving the milling method of EN 24 steel when tungsten carbide inserts are utilised. Understanding the milling process in its entirety is facilitated by SEM analysis of surface morphologies and microstructures under particular cutting conditions. The morphology and surface irregularities of the machined workpiece are evaluated using profilometry, which provides additional insight into surface integrity. The discourse investigates the potential applications and implications of the results, as well as suggests directions for further study concerning the enhancement of milling processes for similar steel alloys.

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Section: Mathematical Modelling and Regression Analysismentioning

confidence: 99%

Optimization of surface roughness in milling of EN 24 steel with WC-Coated inserts using response surface methodology: analysis using surface integrity microstructural characterizations

Patil,

Sathish,

Rao

et al. 2024

Front. Mater.

Self Cite

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“…Therefore, there is a large gap in the study of residual stresses formed by ultrasound-assisted grinding. The main reasons for the formation of grinding residual stresses are mechanical stresses, thermal stresses and phase transition stresses [15][16][17]. Micro-grinding experiments on aluminum alloy 7075-T6 material by Zhao et al [18] showed that residual compressive stresses occur on the machined surface when the feed rate is below a critical value.…”

Section: Introductionmentioning

confidence: 99%

Mechanism and prediction of residual stress generation in ultrasonic vibration-assisted grinding of bearing steel

Zhang,

Luan,

Zhao

et al. 2024

Preprint

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The surface residual stress of the parts has an important influence on their performance. The generation mechanism of surface residual stress in ultrasonic vibration-assisted grinding (UVAG) of bearing steel was investigated, and the correlation between processing parameters and residual stresses was obtained. Based on the ultrasonic vibration-assisted grinding force and thermal model and the flow stress model considering the initial material microstructure, the mechanical and thermal stresses of the material were calculated. Finally, the theoretical model of residual stress is established based on the yield theory and experimentally verified. High-speed ultrasonic aerostatic spindle for ultrasonic vibration-assisted grinding, change the inlet pressure to realize the ultrasonic amplitude and frequency adjustment, the experimental results show that the cutting direction and the vertical cutting direction of the residual stress test results and the model prediction results of the average relative error of 11.4% and 11.7%, and the rule of change is more consistent. Based on the experimental results, the influence pattern of process parameters on the experimental results was analyzed. The results show that the residual compressive stress on the surface of ultrasonic vibration-assisted grinding is directly proportional to the grinding depth, feed rate, and inlet pressure of pneumatic ultrasonic wave, and inversely proportional to the linear speed of the grinding wheel. This study provides a theoretical basis for the analysis of UVAG residual stress and optimization of UVAG process parameters.

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Mechanism and prediction of residual stress generation in ultrasonic vibration-assisted grinding of bearing steel

Zhang,

Luan,

Zhao

et al. 2024

Int J Adv Manuf Technol

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Residual stress generation in grinding: Mechanism and modeling

Cited by 17 publications

References 131 publications

Optimization of surface roughness in milling of EN 24 steel with WC-Coated inserts using response surface methodology: analysis using surface integrity microstructural characterizations

Optimization of surface roughness in milling of EN 24 steel with WC-Coated inserts using response surface methodology: analysis using surface integrity microstructural characterizations

Mechanism and prediction of residual stress generation in ultrasonic vibration-assisted grinding of bearing steel

Mechanism and prediction of residual stress generation in ultrasonic vibration-assisted grinding of bearing steel

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