Force prediction in micro-grinding maraging steel 3J33b considering the crystallographic orientation and phase transformation

Abstract

In micro-grinding, the effects of crystallography on grinding force become significant since the depth of cut is of the same order as the grain size. In this research, the Taylor factor model for multi-phase materials is proposed based on the previously reported Taylor factor model for monocrystalline material. Based on this model, the flow stress model is developed, which takes both the effect of CO on the athermal stress and the stress induced by the phase transformation into account. Based on the flow stress model, the predictive model of chip formation force is proposed by adapting parallel-sided shear zone theory. The rubbing force is modeled by applying Waldorf’s worn tool theory. Furthermore, the plowing force is predicted based on previously reported model by the authors. Subsequently, a comprehensive model of the micro-grinding force is proposed by considering mechanical-thermal loading, the effects of crystallography, and phase transformation. Finally, the model is validated by conducting an orthogonal-designed experiment with the result proving that the prediction of the model is capable to capture the magnitude and trend of the experimental data. Moreover, the proposed analysis are compared with the predictions of two other previously reported models with the result, indicating that the model that considers the effect of CO and the phase transformation improves the accuracy of the micro-grinding force.