Abstract
Residual stresses have an important role concerning service life of forming tools. The grinding of the tool is one of the major manufacturing steps inducing residual stresses into the subsurface of the tool. Tool and process parameters for grinding with toric grinding pins have been investigated for their influences on residual stresses and surface finish. Residual stresses were measured using the sin2ψ method, while the surface finish was analyzed using white light confocal microscopy. Results show that the grinding strategy has a major influence on residual stress generation for both principle directions of the process. In addition cutting grain size has the major impact on residual stresses transverse to cutting direction, while feed rate has the main influence on residual stresses in cutting direction. A bigger grain size results in more compressive residual stresses, while a higher feed rate shifts stresses towards the tensile regime. A good surface finish is achieved with small cutting grain size, low feed rates and frontal grinding strategy.
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