INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN

N 0976 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) IAEME AND TECHNOLOGY (IJMET)
ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 3, Issue 3, September - December (2012), pp. 344-349 IAEME: www.iaeme.com/ijmet.asp Journal Impact Factor (2012): 3.8071 (Calculated by GISI) www.jifactor.com

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MODELING AND ANALYSIS OF SURFACE GRINDING FOR RESIDUAL STRESSES IN WORKPIECE

Gunwant D.Shelake M.E.(Mfg.) JNEC, Aurangabad MH. India gunwantshelake@gmail.com Harshal K. Chavan M.E.(Mfg.) JNEC, Aurangabad MH. India gunwantshelake@gmail.com Prof. R. R. Deshmukh Dept. of Mechanical Engg. JNEC, Aurangabad MH. India prithardeshmukh@gmail.com Dr. S. D. Deshmukh Principal, JNEC, Aurangabad MH. India sdeshmukh47@rediffmail.com

ABSTRACT Thermal damage and residual stresses [1] are responsible for defects in grinding process, so it is important to study the factors which affect grinding temperatures. This paper presents an overview of effect of various grinding parameters on residual stresses. Then general analytical approach consists of modeling the grinding zone as a heat source which moves along the work piece surface. A critical factor for calculating grinding temperatures is the energy distribution [2], which is the fraction of the grinding energy transported as heat to the work piece at the grinding zone.. In this paper, a finite element thermo mechanical model for the calculation of effect of residual stresses by a surface grinding process on a steel work piece (AISI 52100) is presented. A model giving the energy conducted as heat in the work piece as a function of the grinding wheel [3] speed, the work piece speed, and the cutting depth is proposed Keywords: Thermal damage, temperature distribution , residual stresses, finite element model 1. INTRODUCTION The amount of energy per unit volume of material being removed from the work piece during grinding is very large. This energy is converted entirely almost into heat, causing a significant rise in the work piece temperature and, therefore thermal damage and residual stresses. In order to analyze this extensive work has been performed pertaining to the modeling and simulation of grinding. Structural modeling that can predict the residual stresses within the work piece have been developed. A 2D model was used, with the grinding width large with respect to its length. However, this model is based on the assumption that the total grinding
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) IAEME

energy is entirely absorbed by the work piece, whilst in reality the total grinding energy is distributed not only in the work piece but also in the grinding wheel, the chip, and the coolant [4]. The finite element method[5] has been employed for modeling the grinding process, in order to achieve a greater accuracy and more reliable results. In the present paper, a novel finite element thermal models reported, which allows for the calculation of the residual stresses and their distribution within the work piece. The maximum stress on the surface and the stresses developed in the subsurface of the work piece during grinding can be theoretically predicted using the model [6]. 2. KINEMATICS OF GRINDING

Fig. 1 schematic representation of a grinding Fig. 1 shows a schematic representation of a grinding process. Here a wheel rotating with a surface velocity of Vs moves against the surface of workpiece with relative velocity of Vwp. During the process an amount of a i.e .depth of cut is removed from the surface. The contact length between wheel and workpiece is calculated from equation (1)in which lc is contact length, ds is diameter of wheel and a, as mentioned before is depth of cut that is removed in one pass. The heat flux [7] that exerts to the workpiece during grinding can be calculated from equation (2) where q is heat flux into the workpiece, is percentage of heat flux entering into the workpiece, Ft is tangential force that produced during engagement of wheel and workpiece and b is the grinding width. The proportion of heat flux entering the workpiece can be calculated by equation (3) where uch is the energy required for chip formation having a constant value of 13.8 J/mm3 for grinding all ferrous materials and u is the total specific energy required for grinding [8] 3. THERMAL MODELING OF GRINDING The grinding wheel is considered to be a moving heat source, see Fig. 1. The heat source is characterized by a physical quantity, the heat flux, q, that represents the heat entering an area of work piece per unit time and is considered to be of the same density along its length, which is taken equal to the geometrical contact length, lc, which is calculated from the relation [9] = . (1) Where a is the depth of cut and ds is the diameter of the grinding wheel.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) IAEME

Fig. 2.Suggested thermal finite element model for surface grinding

The real contact length is expected to be larger to the deflection of the grinding wheel and the workpiece in the contact area. Assuming the geometrical and real contact lengths are considered to be equal. The heat flux can be calculated from the following equation =

(2)

Where, is the percentage of heat flux entering the workpiece, f = the tangential force per unit width of the workpiece, vs =the peripheral wheel speed and lc = the geometrical contact length. The proportion of the heat flux entering the workpiece can be calculated by a formula suggested by Malkin for grinding with aluminum oxide wheels, as =1 (3) where is the energy required for chip formation, having aconstant value of about 13.8 J /mm3 for grinding all ferrous materials, and u is the total specific grinding energy required for grinding, calculated from u= (4)

where v is the workspeed. Note that, in both Eqs (2) and (4), the value of Ft is required in order to calculate the heat flux and the total specific grinding energy, respectively; it can be calculated from f = (5)

Where Pt is the power per unit width of the workpiece, which was measured during the testing of the different grinding wheels. Therefore, from Eqs (2)(5), the heat flux can be calculated for every case. The kind of modeling suggested in this paper is suitable for a grinding process with a very small depth of cut, since there is no modeling of the chip. In any other case, other assumptions must be made for the chip in order to provide a valid model, since the heat carried away by the chip cannot be neglected. Furthermore, the two coefficients of the work piece material that are related to temperature, i.e. the thermal conductivity and the specific heat capacity, along with the density of the work piece must be inserted as inputs to the program. For the material used in the wheel testing, those quantities were taken from the FEM program data bank. The first two were considered to be temperature dependent [10].

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) IAEME

4. FINITE ELEMENT MODEL The process of grinding is carried out by movement of the grinding wheel against a stationary workpiece. During this process, surface of work piece comes into contact with abrasive grains of grinding wheel and a certain amount of material is removed from it. At any defining moment contact occurs in a specific length of work piece called contact length in which thermal exchange and mechanical forces are introduced into the workpiece. The problem of grinding can be described by moving an appropriate heat flux and mechanical forces on the top surface of work piece, mathematically .A two dimensional model was used to simulate movement of heat flux on the surface of work piece using the ANSYS [11] finite element analysis package. Since loading and geometry remains unchanged in the third direction, a two dimensional plane strain model would be appropriate for obtaining temperature and stress field. The finite element mesh is shown in Fig. 2. AISI 52100 bearing steel which is widely used for grinding was considered for work piece material. Structural analysis was carried out, step by step, by exerting calculated heat flux into the contact length. Assumptions made in finite element models are Grinding process is transient in nature. Material is homogeneous and isotropic Material properties [12] are assumed to be linear. 5. RESULTS Figure 5a, 5b & 5c shows temperature results when the wheel is about to leave the workpiece. From figure 5a &5b we can say that maximum temperature occurs at the trailing edge but due to ambient there is no temperature rise after the trailing edge.
X stress 0.00E+00 -1.00E+07 Stress (Pa) -2.00E+07 -3.00E+07 -4.00E+07 -5.00E+07 -6.00E+07 -7.00E+07 0.000 0.002 0.004 0.006 0.008 0.010 0.012 Distance (m) Low Medium High

Fig.5a Stress along X axis

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) IAEME
Y stress 0.00E+00 -1.00E+06 Stress (Pa) -2.00E+06 -3.00E+06 -4.00E+06 -5.00E+06 -6.00E+06 -7.00E+06 0.000 0.002 0.004 0.006 0.008 0.010 0.012 Distance (m) Low Medium High

Fig.5b Stress along Y axis

Fig.5c Max.Stress 6. CONCLUSION It can be concluded that the Finite Element Model yields a good understanding of the process and aids to make suitable changes to process parameters to affect the desired thermal loading and which may hence affect the residual stresses [13] in the model. Further, recently there has been some work related to the use of grinding for causing heat treatment owing to the substantial heat generated and high temperature on the ground surface, the finite element model can aid to decide suitable parameters (speed, feed) to determine the best course for attaining such heat treatment. The model also incorporates cooling effects (through surface convection) which can be used to compare the cooling effectiveness of the coolants to be used. Since high temperature occurs at the trailing edge of the grind interface (also called as the burnout effect), one must ensure that large amount of coolant is used and that it penetrates the grind zone to be effective. Similarly when feed rate increases by 90% X-stress along the
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) IAEME

grinding path increases by 9% & Y-stress along the grinding path increases by 4%, X-elastic strain along the grinding path increases by 10%, Y-elastic strain along the grinding path increases by 3%. REFERENCES 1. 2. 3. 4. 5. 6. 7. 8. 9. R. J. Gu, M. Shillor,G. C. barber,T. Jen,July 2003:Thermal Analysis of the Grinding Process. Bin Shen1,Albert J. Shih,Guoxian Xiao, June 2011:A Heat Transfer Model Based on Finite Difference Method for Grinding. T. Brockhof, January 10, 1999: Grind-Hardening: A Comprehensive View. Maklin S., 1989, Grinding Technology: Theory and Application of Machining with Abrasive, SME,Dearbon. D.A.Doman, A.Warkentin, R.Bauer, 1November 2008: Finite element modeling approaches in grinding. Snoeys ,R., Maris, M and Peters , J., 1978,Thermally Induced Damages in Grinding, Annals of the CIRP, p.571 Aaron Walsh, February, 2004 :MATHEMATICAL MODELLING OF THE CRANKSHAFT PIN GRINDING PROCESS Guo, C. And Malkin, S., 1994, " Analytical and Experimental Investigation of Burnout in Creep-Feed Grinding Kohli, S.P., Guo, C., Malkin, S., 1995, "Energy Partition for Grinding with Aluminium Oxide and CBN Abrasive wheels", ASME Journal of Engineering for Industry, Vol.117, pp. 160-168 Jaeger J. Moving Sources of Heat and Temperature at Sliding Contacts," Proc. Of the Royal Society of New South Wales, Vol. 76,1942, pp. 203-224 Ansys user manual. P.N. Moulik1, H.T.Y. Yang2, S. Chandrasekar*,10 February 2000 :Simulation of thermal stresses due to grinding HdiHamdi, Hassan Zahouani, Jean-Michel Bergheau,26 February 2003:Residual stresses computation in a grinding process

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