Abstract
Grind-hardening processing is an emerging approach that combines the grinding and surface quenching process. During the process, the hardened layer—mainly martensite—is produced on the surface of the workpiece to achieve the purpose of surface strengthening. Above all, the surface temperature field of the hypoeutectoid-1045 steel workpiece was determined by finite element method for fully revealing the formation mechanism of the hardened layer. Further, the cellular automata approach was applied to dynamically simulate the transformation of both austenitization and martensitization from the initial microstructure. The hardness penetration depth was also predicted. Finally, a grind-hardening experiment was conducted to assess the theoretical study. Results showed that a combination of the finite element method and the cellular automata approach can effectively simulate the microstructure transformation of hardened layer. The microstructure and the hardness penetration depth were affected by the maximum grinding temperature and the heating rate. Research on the influence of grinding parameters showed that the hardness penetration depth increased as the depth of the wheel cut and feeding speed increased. Experiments revealed that the difference between predicted value and experimental value of the hardness penetration depth varied between 2.83% and 7.31%, which confirmed the effectiveness of the predicted model.
Highlights
Grind-hardening is an emerging technology for compound machining on the ground surface
Basing on the heating source model, the temperature field of 1045 steel workpiece during the grinding process is simulated by finite element method (FEM)
The analysis shows that when the wheel is grinding on this position, the grinding temperature rises rapidly, and the highest temperature of the surface is higher than Ac3
Summary
Grind-hardening is an emerging technology for compound machining on the ground surface. This technology uses extremely high grinding heat generated during the grinding process to increase the surface temperature of the part to the austenitizing temperature in a short time. The advantages of grind-hardening technology are obvious: (1) The effective combination of grinding and surface hardening simplifies the processing procedure, reduces energy consumption and improves productivity and economic benefits; (2) Compared with other grinding methods, grind-hardening technology cannot only make parts achieve higher machining accuracy, and make the surface form a martensite microstructure, which significantly enhances its application performance in engineering (fatigue strength, wear resistance and corrosion resistance, etc.) [3]. Brinksmeire and Brockhoff et al [4,5] carried out basic research on the grind-hardening process, using AISI 4140 steel and AISI E52100 steel as experimental materials, for revealing the factors
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