A New Perspective of Residual Stress Induced by Machining and Grinding

Abstract

Abstract Residual stress is one of the most important factors affecting product surface integrity. Every machining operation produces a distinctive residual stress in the surface layer. The surface residual stress produced by grinding and face turning were measured in very small surface areas at several locations of each sample using X-Ray diffraction technique. Significant point-to-point residual stress variations were found in the ground surfaces, which poses a potential hazard to applications requiring high surface integrity. On the other hand, only small point-to-point residual stress variations were found in the face turned surface. An explanation to this phenomenon has been given. Residual stress on seven samples undergone multiple-pass grinding were also measured, the results of which show that final residual stress distribution on a ground workpiece depends on the initial residual stress, the number of grinding pass, as well as grinding conditions. It is suggested that single-point cutting be used in place of abrasive grinding.