Salonitis Grind Hardening Process

1. Auflage 2015
ISBN: 978-3-319-19372-4
Verlag: Springer International Publishing
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 102 Seiten

Reihe: Manufacturing and Surface Engineering

This book presents the grind-hardening process and the main studies published since it was introduced in 1990s. The modelling of the various aspects of the process, such as the process forces, temperature profile developed, hardness profiles, residual stresses etc. are described in detail. The book is of interest to the research community working with mathematical modeling and optimization of manufacturing processes.

Autoren/Hrsg.

Salonitis, Konstantinos

Inhaltsverzeichnis

1;Preface;7
2;Contents;8
3;1 Hybrid Processes for Surface Modification and the Grind-Hardening Process;11
3.1;Abstract;11
3.2;1.1 Introduction;11
3.3;1.2 Principles of Surface Modification;12
3.4;1.3 Surface Hardening Methods;13
3.4.1;1.3.1 Induction Hardening;13
3.4.2;1.3.2 High Frequency Resistance Hardening;14
3.4.3;1.3.3 Flame Hardening;15
3.4.4;1.3.4 Laser Beam Hardening;16
3.4.5;1.3.5 Electron Beam Hardening;17
3.4.6;1.3.6 Electrolytic Hardening;17
3.5;1.4 Hybrid Surface Modification Methods;18
3.5.1;1.4.1 Grind Hardening;18
3.5.2;1.4.2 Hot Stamping;19
3.5.3;1.4.3 Cryogenic Deep Rolling and Hardening;19
3.5.4;1.4.4 Maturity of Hybrid Processes;20
3.6;References;20
4;2 Grind-Hardening State-of-the-Art;22
4.1;Abstract;22
4.2;2.1 Introduction;22
4.3;2.2 Grind-Hardening Process Overview;23
4.4;2.3 Fundamental Mechanisms in Grind Hardening;24
4.5;2.4 Alternative Process Chains;26
4.6;2.5 Fundamental Investigations—Feasibility Studies;26
4.6.1;2.5.1 Workpiece Material;27
4.6.2;2.5.2 Workpiece Geometry;30
4.6.3;2.5.3 Grinding Wheel;31
4.6.4;2.5.4 Process Parameters;32
4.7;2.6 Simulation of the Grind-Hardening Process;34
4.8;2.7 Challenges for Future;35
4.9;References;36
5;3 Grind-Hardening Process Modelling;41
5.1;Abstract;41
5.2;3.1 Introduction;41
5.3;3.2 Grinding Kinematics—Grinding Wheel Topography;42
5.3.1;3.2.1 Static Grains;43
5.3.2;3.2.2 Active Grains;45
5.4;3.3 Process Forces Semi-empirical Modelling;47
5.4.1;3.3.1 Sliding Forces;47
5.4.1.1;3.3.1.1 Average Contact Pressure;48
5.4.1.2;3.3.1.2 Actual Area of Contact;49
5.4.1.3;3.3.1.3 Friction Coefficient;49
5.4.1.4;3.3.1.4 Sliding Forces;50
5.4.2;3.3.2 Cutting Forces;50
5.4.3;3.3.3 Model Implementation and Validation;51
5.5;3.4 Modelling Heat Generation and Partition;52
5.5.1;3.4.1 Heat Partition;54
5.5.2;3.4.2 Heat Dissipation by the Chips;56
5.5.3;3.4.3 Heat Dissipation by the Grinding Wheel;56
5.5.4;3.4.4 Heat Entering the Workpiece;58
5.5.5;3.4.5 Model Implementation and Validation;58
5.6;3.5 Modelling of Temperature Distribution;59
5.6.1;3.5.1 Modelling of Prismatic Workpiece Geometries;60
5.6.1.1;3.5.1.1 Dry Grind Hardening;61
5.6.1.2;3.5.1.2 Wet Grind Hardening;61
5.6.1.3;3.5.1.3 Final Cooling Stage;62
5.6.1.4;3.5.1.4 Temperature Distribution Calculation;63
5.6.2;3.5.2 Modelling of Cylindrical Workpiece Geometries;63
5.6.2.1;3.5.2.1 Dry Grind Hardening;64
5.6.2.2;3.5.2.2 Wet Grind Hardening;64
5.6.2.3;3.5.2.3 Final Cooling Stage;65
5.6.3;3.5.3 Modelling Using Finite Element Analysis;66
5.6.4;3.5.4 Model Implementation and Validation;67
5.7;3.6 Modelling of Metallurgical Changes;68
5.7.1;3.6.1 Introduction Surface Heat Treatment Mechanisms;68
5.7.2;3.6.2 Austenitization Temperature;71
5.7.3;3.6.3 Martensitization Temperature;72
5.7.4;3.6.4 Retained Austenite;74
5.7.5;3.6.5 Micro-Hardness;74
5.7.6;3.6.6 Hardness Penetration Depth;75
5.7.6.1;3.6.6.1 Maximum Achievable Hardness Penetration Depth;75
5.7.7;3.6.7 Model Implementation and Validation;76
5.7.7.1;3.6.7.1 CCT Diagram Modification;76
5.7.7.2;3.6.7.2 Hardness Distribution Estimation;77
5.7.7.3;3.6.7.3 Hardness Penetration Depth Estimation;78
5.8;3.7 Modelling of Residual Stresses;79
5.8.1;3.7.1 Modelling Using Finite Element Analysis;80
5.8.2;3.7.2 Model Implementation and Validation;81
5.9;3.8 Integration of Models;82
5.9.1;3.8.1 Integrated Model and Database Validation;82
5.10;References;86
6;4 Energy Efficiency and Environmental Impact Implications of Grind-Hardening Process;89
6.1;Abstract;89
6.2;4.1 Introduction;89
6.3;4.2 Energy Efficiency;90
6.4;4.3 Environmental Impact Assessment;93
6.4.1;4.3.1 Introduction to Life Cycle Assessment;93
6.4.2;4.3.2 Technical Framework of Life Cycle Assessment;94
6.4.3;4.3.3 Grind-Hardening LCA-Based Environmental Impact Assessment;96
6.5;References;98
7;5 Concluding Remarks and Outlook;100
7.1;Abstract;100
7.2;5.1 Introduction;100
7.3;5.2 Summary;101
7.4;5.3 Outlook;101
7.5;References;102