<p>Residual stress is an important mechanical property parameter and a key evaluation index of the surface integrity。Residual stress induced in micro-grinding micro-grinding is related to the process parameters, the wheel properties, and microstructure of the material.&nbsp;The micro-grinding process is distinct from the conventional grinding owing to size effect, and the crystal effect becomes more significant owing to the depth of cut less than the average grain size. Typically, the effects of crystallographic orientation (CO) on process behaviors are significant by influencing the flow stress of workpiece material due to the depth of cut is usually less than the average grain size. In this paper, a Taylor factor model is developed to estimate the effect of CO on the flow stress. The flow stress model takes into account two parts including thermal effect and athermal effect. Thermal effect is related to strain, strain rate, and temperature; athermal effect is related to material microstructure including grain size, CO, and dislocation density. The plastic modulus of monocrystalline materials h is given as the function of hardness, strain, and microstructure. To understand the residual stress generated in the micro-grinding clearly, the paper analytically investigates this process by focusing on the grinding force, grinding temperature, and the contact stress with force and temperature coupled with flow stress. Then, the analytical model of residual stress is proposed considering the effects of CO and the hybrid McDowell algorithm to predict the residual stress with the developed plastic modulus. The calculation of residual stress induced by mechanical and thermal load includes the stress loading and stress relaxation in micro-grinding. The residual stress predicted by the proposed model are compared to the classic residual stress model which don’t consider the variation of Taylor factor in the flow stress and the plastic modulus. The result shows that the residual stress is closely related to the Taylor factor including the maximum compression stress and the penetration of residual stress. Furthermore, the compressive stress changes to be tension stress when the Taylor factor increase up to a critical value. In addition, the modulus plasticity modulus is significantly affected by the material COs and increases with the Taylor factor. Finally, to better understanding the effect of Taylor factor on residual stress induced by the micro-grinding of single-crystal copper, the sensitivity analysis are conducted in the section, with the result showing that the effect of CO on residual stress is significant. It will contribute to provide a process parameters optimization of micro-grinding residual stress.</p>

Modeling of Residual Stress Induced in Micro-Grinding Considering Texture Effect

Paper Proceedings: https://asmedigitalcollection.asme.org/IMECE/IMECE2021/volume/85543

ASME 2021 International Mechanical Engineering Congress and Exposition (IMECE2021)

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