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

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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.