Experimental and Numerical Analysis of Residual Stress Change Caused by Thermal Loads During Grinding

A realistic modelling and simulation of the resulting surface integrity e.g residual stresses caused by grinding is limited due to the lack of knowledge to estimate the amount of thermal load affecting the workpiece. This paper deals with the inverse determination of the heat partitioning during grinding and the prediction of the resulting residual stress state due to the thermal impact by using 2D FEM-simulation without phase transformations. Grinding tests have been performed and the temperatures beneath the contact zone have been measured. For the first time, the concept of Process Signatures is applied on a machining process, providing basic functional relationships for process quantities, internal material loads and material modifications for predominantly thermal loads.