Computer Based Grinding Model to Predict Temperature Residual Stress and Phase Transformation Distribution in the Workpiece

本项目涉及平面磨削计算机模型的开发。本研究的目的是预测加工参数，以减少工件损伤和优化表面质量。数学模型应该允许计算温度和应力场，任何热诱导相变的程度和残余应力的大小。该模型考虑了完全耦合的热-力学场方程，通过能量平衡方程中任意相变时的膨胀功、塑性功和热量释放进行耦合。在先前的拨款（DMC-8414917）下开发的简单有限元模型提供了合金钢（AISI 4340），碳钢（AISI 1038）和不锈钢（AISI 304）的磨削数据，这些数据与实验数据在定量上一致。目前的工作将改进以前的模型，以提高其适用性，计算速度和准确性。将进行参数研究，以确定磨削过程的关键工艺参数。一旦这些计算完成，将尝试开发第二代计算机模型，该模型将改进计算过程和模型中使用的材料属性。此外，该模型将扩展到检查额外的磨削工艺，如多道次和外圆磨削。

This project deals with the development of a computer model for surface grinding. The goal of this research is to predict the processing parameters in order to minimize workpiece damage and optimize surface quality. The mathematical model should permit calculation of the temperature and stress fields, the extent of any thermally induced phase transformations and the magnitude of the residual stresses. The model considers the fully coupled thermomechanical field equations, with coupling through the dilatational work, the plastic work, and the heat release during any phase transformation in the energy balance equation. A simple finite element model developed under a previous grant (DMC-8414917) provided data on grinding of an alloy steel (AISI 4340), a carbon steel (AISI 1038), and a stainless steel (AISI 304) which are in quantitative agreement with experimental data. The present work will refine the previous model to enhance its applicability, computational speed, and accuracy. Parametric studies will be made to identify critical process parameters of the grinding process. Once these computations are completed, attempts will be made to develop a second generation computer model which will refine both the computational process and the material properties used in the model. In addition, the model will be extended to examine additional grinding processes such as multiple pass and cylindrical grinding.