Prediction of grinding residual stresses

Residual stresses due to machining are the results of the thermo-mechanical history of the piece/tool interface. The magnitude and the gradient of stress play a key role for the surface integrity. A thermo-mechanical model has been developed. It allows simulating the rolling/sliding contact between an elastic tool in rotation along its own axis and an elastic-plastic flat in translation. The analysis includes the effects of both the normal and tangential loading. Frictional heating is also considered. The model is based on a semi-analytical method and the transient 3D contact problem is fully solved. Compared to the finite element method the computing time is reduced by several orders of magnitude. This technique has already been successfully applied to the simulation of running-in and wear, and to fretting wear, and a first attempt to simulate residual stress and strain due to the contact between a grinding tool and a work piece is made here. First results are presented for various stationary and transient thermo-mechanical loading histories.