Hardness Penetration Depth Prediction in the Grind-Hardening Process through a Combined FEM model

Abstract

The grind-hardening process aims to increase the surface hardness of the material through the dual action of the mechanical and thermal load. A novel approach to model the process and predict the hardness penetration depth was developed based exclusively on the prediction of austenite-martensite transformation. A combined micro and macro scale approach was implemented to forecast the temperature reached in the surface starting from the action of a single grain and using its specific cutting power to design a moving heat source representing the interaction between the grinding wheel and the material. The martensitic transformation temperature considered in this paper takes into consideration the fast heat cycle typical of this process. In order to validate the model, tangential surface grinding tests were performed on 42CrMo4 and microstructural analysis with micro-hardness measurements were performed. This research presents a first step in developing a grinding process simulation that includes multi-grain grinding, real grain geometries, binder effect, and real workpiece-grinding wheel kinematics.