Surface hardness improvement in high efficiency deep grinding process by optimization of operating parameters

Abstract

The grinding is one of the most important methods that directly affects tolerances in dimensions, quality and finished surface of products. One of the major problems in the material removal processes specially grinding is the heat generation during the process and the residual tensile stress in the surfaces of product. Therefore, optimization of High Efficiency Deep Grinding (HEDG) process is the main goal of this study to reduce the generated heat and residual tensile stress and increase strength and surface hardness of AISI1045 annealed steel. To this end, the effects of main parameters e.g. depth of cut, wheel speed, workpiece speed and cross feed on surface hardness has been investigated. The experimental results demonstrated the reduction in surface temperature and increase in hardness as optimum conditions are applied to the grinding process. Moreover, the experimental results were validated by comparing with other experimental results and analyzing of surface microhardness, surface temperature and normal and tangential forces.