Experimental Study on In-Depth Residual Stress due to 420 Stainless Steel Creep-Feed Grinding Using the Deflection-Electro Polishing Technique

Subject Areas :

Vahid Jafarpour ¹ , Rasoul Moharrami ²

1 - Department of Mechanical and Aerospace Engineering, University of Texas at Arlington, Texas, USA
2 - Engineering Faculty, University of Zanjan, Zanjan, Iran

Received: 2022-04-04 Accepted : 2022-05-14 Published : 2022-02-01

Keywords: Residual stresses, creep-feed grinding, small quantity cooling lubrication, Electro-polishing,

Abstract :

In the current study, the deflection-electro polishing method was used to evaluate through-thickness residual stresses. A modified equation was developed to calculate the non-uniform residual stresses of creep-feed ground plates concerning the three-order polynomial curve fitting of the deflection in the specimens. Employing the current density of 825 A/m2 for the specimens caused stressed materials to be removed from their surface with the corrosion rate of 1 µ/min, which facilitated estimating the thickness of the removed layers concerning corrosion time. To investigate residual stresses created by creep-feed grinding, three different cooling conditions, i.e. dry, flood, and small quantity cooling lubrication (SQCL) were tested. The literature review showed a dearth of research on through-thickness residual stresses under SQCL creep-feed grinding. The results demonstrated that due to a considerably lower flow rate of the SQCL compared to that of the flood cooling system, considerable performance was detected so that compressive residual stresses were observed in the depth beneath the surface.

References:

[1] Kim, H.J., Kim, N.K. and Kwak, J.S. 2006. Heat Flux Distribution Model by Sequential Algorithm of Inverse Heat Transfer for Determining Workpiece Temperature in Creep Feed Grinding. International Journal of Machine Tools and Manufacture. 46(15): 2086–2093.

[2] Jin, T. and Stephenson, D.J. 2003. Investigation of the Heat Partitioning in High-Efficiency Deep Grinding. International Journal of Machine Tools and Manufacture. 43(11):1129–1134.

[3] Lavisse, B., Lefebvre, A., Torrance, A.A., Sinot, O., Henrion, E., Lemarié, S. and Tidu, A. 2018. The Effects of the Flow Rate and Speed of Lubricoolant Jets on Heat Transfer in the Contact Zone when Grinding a Nitrided Steel. Journal of Manufacturing Processes. 35: 233-243.

[4] Jamshidi, H. and Budak, E. 2018. Grinding Temperature Modeling Based on a Time Dependent Heat Source. 8th CIRP Conference on High Performance Cutting. Procedia CIRP. 77: 299–302.

[5] Jin, T. and Stephenson, D.J. 2006. Heat Flux Distributions and Convective Heat Transfer in Deep Grinding. International Journal of Machine Tools and Manufacture. 46(14):1862–1868.

[6] Kohli, S., Guo, C. and Malkin, S. 1995. Energy Partition to the Workpiece for Grinding with Aluminum Oxide and CBN Abrasive Wheels. Journal of Engineering for Industry.117 (2): 160-168.

[7] Jafarpour, V. and Moharrami, R. 2022. Numerical Stress Analysis of Creep-Feed Grinding Through Finite Element Method in Inconel Alloy X-750. Mapta Journal of Mechanical and Industrial Engineering (MJMIE). 6(1): 1–9.

[8] Liu, M., Nguyen, T., Zhang, L., Wu and Q., Sun, D. 2015. Effect of Grinding-induced Cyclic Heating on the Hardened Layer Generation in the Plunge Grinding of a Cylindrical Component. International Journal of Machine Tools and Manufacture. 89: 55–63.

[9] Ding, W., Zhang, L., Li, Z., Zhu, Y., Su, H. and Xu, J. 2017. Review on Grinding-induced Residual Stresses in Metallic Materials. The International Journal of Advanced Manufacturing Technology. 88: 2939–2968.

[10] Cearsolo, X., Cabanes, I., Sanchez, J.A., Pombo, I. and Portillo, E. 2016. Dry-dressing for Ecological Grinding. Journal of Cleaner Production. 135: 633-643.

[11] Saberi, A., Rahimi, A.R., Parsa, H., Ashrafijou, M. and Rabiei, F. 2016. Improvement of Surface Grinding Process Performance of CK45 Soft Steel by Minimum Quantity Lubrication (MQL) Technique Using Compressed Cold Air Jet from Vortex Tube. Journal of Cleaner Production. 131: 728-738.

[12] Sinha, M. K., Madarkar, R., Ghosh, S. and Rao, P. V. 2017. Application of Eco-friendly Nanofluids during Grinding of Inconel 718 through Small Quantity Lubrication. Journal of Cleaner Production. 141:1359-1375.

[13] Verma, N., Kumar, M. K. and Ghosh, A. 2017. Characteristics of Aerosol Produced by an Internal-mix Nozzle and its Influence on Force, Residual Stress and Surface Finish in SQCL Grinding. Journal of Materials Processing Technology. 240: 223–232.

[14] Sai, S. S., Kumar, K. M. and Ghosh, A. 2015. Assessment of Spray Quality from an External Mix Nozzle and its Impact on SQL Grinding Performance. International Journal of Machine Tools and Manufacture. 89: 132–141.

[15] Paul, S. and Ghosh, A. 2017. Suitability of Aqueous MoS2 Nanofluid for Small Quantity Cooling Lubrication–assisted Diamond Grinding of WC-Co Cermets. Proceedings of the Institution of Mechanical Engineers. Part B: Journal of Engineering Manufacture. 233(2): 426-442.

[16] Debnath, S., Reddy, M.M. and Yi, Q.S. 2014. Environmental Friendly Cutting Fluids and Cooling Techniques in Machining: A Review. Journal of Cleaner Production. 83: 33-47.

[17] Kumar, M. K. and Ghosh, A. 2015. Synthesis of MWCNT Nanofluid and Evaluation of its Potential besides Soluble Oil as Micro Cooling-lubrication Medium in SQL Grinding. The International Journal of Advanced Manufacturing Technology. 77: 1955–1964.

[18] Roy, S., Ghosh, A. 2013. High-Speed Turning of AISI 4140 Steel using Nanofluid through Twin Jet SQL System. Proceedings of the ASME International Manufacturing Science and Engineering Conference. 2: 1067.

[19] Woo, W., An, G. B., Em, V. T., De Wald, A. T. and Hill, M. R. 2015. Through thickness Distributions of Residual Stresses in an 80 mm Thick Weld using Neutron Diffraction and Contour Method. Journal of Materials Science. 50(2): 784–793.

[20] Schajer, G. S. 2013. Practical Residual Stress Measurement Methods. John Wiley and Sons.

[21] Harrington, J. S. and Schajer, G. S. 2017. Measurement of Structural Stresses by Hole-drilling and DIC. Experimental Mechanics. 57: 559–567.

[22] Al-Mosawe, A., Agha, H., Al-Hadeethi, L. and Al-Mahaidi, R. 2018. Efficiency of Image Correlation Photogrammetry Technique in Measuring Strain. Australian Journal of Structural Engineering. 19(3):  2204-2261.

[23] Schajer, G.S. and Whitehead, P. S. 2017. Hole-drilling Method for Measuring Residual Stresses. Morgan and Claypool Publishers.

[24] Rossini, N.S., Dassisti, M., Benyounis, K.Y. and Olabi, A.G. 2012. Methods of measuring Residual Stresses in Components. Materials and Design. 35: 72–588.

[25] Moharrami, R. and Jafarpour, V. 2019. Experimental Study of Residual Stresses Due to Inconel X-750 Creep-feed Grinding by the Electropolishing Layer Removal Technique. 4: 65-71

[26] Dreiera, S. and Denkenaa, B. 2014. Determination of Residual Stresses in Plate Material by Layer Eemoval with Machine-integrated Measurement. Procedia CIRP. 24: 103 – 107.

[27] Kruszyński, B., Togo, S. and Wójcik, R. 2003. Possibility to Control Surface Integrity in Grinding. Journal of Manufacturing Science and Technology. 4(1): 22-27.

[28] Gadalińska, E. and Wronicz, W. 2016, Electropolishing Procedure Dedicated to In-depth Stress Measurements with X-ray Diffractometry. Fatigue of Aircraft Structures. 1: 65-72.

[29] Han, W. and Fang, F. 2019. Fundamental Aspects and Recent Developments in Electro Polishing. International Journal of Machine Tools and Manufacture. 139: 1-23.