Abstract
Abstract Grinding processes are often the last step in the value-added chain of high-performance hardened steel components. However, thermo-mechanical loads which can take place during the process can have a detrimental effect on the surface integrity of ground parts, which are generally tested by post-process measurements. In the present study, two different approaches for an in-process inspection of the workpiece surface integrity were assessed using magnetic Barkhausen noise analysis during cylindrical grinding of hardened workpieces. The results showed that both measuring systems are able to detect changes in the surface state of workpieces in-process or directly after grinding in the grinding machine. After preparations to protect the sensors from influences during the grinding process, changes in the residual stress state and a decrease of hardness could be reliably detected. Due to constant contact conditions between sensor and workpiece a high reproducibility of the measurements was achieved.
Highlights
Introduction and state of the artHigh performance automotive components such as gears, bearings or camshafts have to be ground after hardening in order to achieve the required form tolerances and surface qualities
Thermo-mechanical loads which can take place during the process can have a detrimental effect on the surface integrity of ground parts, which are generally tested by post-process measurements
The magnetic Barkhausen noise analysis is well-established in industrial applications as post-process testing method, since it is sensitive against light damages [1, 4, 5]
Summary
High performance automotive components such as gears, bearings or camshafts have to be ground after hardening in order to achieve the required form tolerances and surface qualities Various factors such as clogging of the grinding wheel, insufficient cooling or unadapted rough grinding parameters like high material removal rates can be the reason for negative thermo-mechanical influences on the workpiece surface integrity. Potential of magnetic barkhausen noise analysis zones (white layer) These negative influences summarized under the term “grinding burn” impair the final functional properties of the ground part [1]. The magnetic Barkhausen noise analysis is well-established in industrial applications as post-process testing method, since it is sensitive against light damages [1, 4, 5]
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