Modeling Grinding to Predict Residual Stress Distribution inand the Metallographic Structure of the Workpiece

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Part of the science base required for development of machine systems is knowledge and understanding of the phenomena which occur at the interface between tool and workpiece. These phenomena are generally complex, and the research required to understand them is difficult. Usually several technical disciplines are involved, requiring a team of experts. This research is aimed at understanding what happens in and near workpiece surfaces during the unit operation of grinding. The approach entails both theory and experiment. The theory requires use of mechanical, constitutive, and heat transfer equations, for both surface and cyclindrical grinding. Phase transformations must be taken into account. The finite element method will be used to calculate temperature distributions and residual stress fields. The experiments will be performed on 304 stainless steel, 1040 carbon steel, 4340 alloy steel, and 52100 steel. Measurements will be made of grinding forces, wheel speed, temperatures, residual strains, microhardness, and volume fractions of transformed products. Theoretical and experimental results will then be compared.