Experimentally validated atomistic simulation of the effect of relevant grinding parameters on work piece topography, internal stresses, and microstructure

S. J. EDER; P. G. GRÜTZMACHER; T. SPENGER; H. HECKES; H. ROJACZ; A. NEVOSAD; F. HAAS

doi:10.1007/s40544-021-0523-3

Friction 2022, 10(4): 608-629 https://doi.org/10.1007/s40544-021-0523-3

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Open Access | Issue | Published: 05 April 2022

Experimentally validated atomistic simulation of the effect of relevant grinding parameters on work piece topography, internal stresses, and microstructure

Show Author's Information Hide Author's Information S. J. EDER^{¹^,²}(

), P. G. GRÜTZMACHER^², T. SPENGER^³, H. HECKES^⁴, H. ROJACZ^¹, A. NEVOSAD^¹, F. HAAS^³

1 AC2T research GmbH, Viktor-Kaplan-Straße 2/C, Wiener Neustadt 2700, Austria

2 Institute of Engineering Design and Product Development, TU Wien, Lehárgasse 6—Objekt 7, Vienna 1060, Austria

3 Institute of Production Engineering, Graz University of Technology, Kopernikusgasse 24/I, Graz 8010, Austria

4 Tyrolit - Schleifmittelwerke Swarovski K.G., Swarovskistraße 33, Schwaz 6130, Austria

Keywords:

microstructure, tool wear, large-scale molecular dynamics, surface quality, Revolutions per minute-Synchronous Grinding (RPM-Synchronous Grinding)

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EDER SJ, GRÜTZMACHER PG, SPENGER T, et al. Experimentally validated atomistic simulation of the effect of relevant grinding parameters on work piece topography, internal stresses, and microstructure. Friction, 2022, 10(4): 608-629. https://doi.org/10.1007/s40544-021-0523-3

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Abstract Full text Electronic supplementary material About this article

Abstract

In this work, we present a fully atomistic approach to modeling a finishing process with the goal to shed light on aspects of work piece development on the microscopic scale, which are difficult or even impossible to observe in experiments, but highly relevant for the resulting material behavior. In a large-scale simulative parametric study, we varied four of the most relevant grinding parameters: The work piece material, the abrasive shape, the temperature, and the infeed depth. In order to validate our model, we compared the normalized surface roughness, the power spectral densities, the steady-state contact stresses, and the microstructure with proportionally scaled macroscopic experimental results. Although the grain sizes vary by a factor of more than 1,000 between experiment and simulation, the characteristic process parameters were reasonably reproduced, to some extent even allowing predictions of surface quality degradation due to tool wear. Using the experimentally validated model, we studied time-resolved stress profiles within the ferrite/steel work piece as well as maps of the microstructural changes occurring in the near-surface regions. We found that blunt abrasives combined with elevated temperatures have the greatest and most complex impact on near-surface microstructure and stresses, as multiple processes are in mutual competition here.

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Experimentally validated atomistic simulation of the effect of relevant grinding parameters on work piece topography, internal stresses, and microstructure

Show Author's information Hide Author's Information S. J. EDER^{¹^,²}(

), P. G. GRÜTZMACHER^², T. SPENGER^³, H. HECKES^⁴, H. ROJACZ^¹, A. NEVOSAD^¹, F. HAAS^³

1 AC2T research GmbH, Viktor-Kaplan-Straße 2/C, Wiener Neustadt 2700, Austria

2 Institute of Engineering Design and Product Development, TU Wien, Lehárgasse 6—Objekt 7, Vienna 1060, Austria

3 Institute of Production Engineering, Graz University of Technology, Kopernikusgasse 24/I, Graz 8010, Austria

4 Tyrolit - Schleifmittelwerke Swarovski K.G., Swarovskistraße 33, Schwaz 6130, Austria

Abstract

Keywords: microstructure, tool wear, large-scale molecular dynamics, surface quality, Revolutions per minute-Synchronous Grinding (RPM-Synchronous Grinding)

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Received: 11 December 2020

Revised: 26 February 2021

Accepted: 29 April 2021

Published: 05 April 2022

Issue date: April 2022

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Acknowledgements

This work was funded by the Austrian Research Promotion Agency FFG (Project SyFi, No. 864790). Part of this work was funded by the Austrian COMET- Program (Project K2 InTribology1, No. 872176) and carried out at the "Excellence Centre of Tribology" . The computational results presented have been achieved using the Vienna Scientific Cluster (VSC). The government of Lower Austria is gratefully acknowledged for financially supporting the endowed professorship tribology at the Vienna University of Technology (Grant No. WST3-F-5031370/001-2017) in collaboration with AC2T research GmbH. The authors wish to thank Katharina Newrkla and Ulrike Cihak-Bayr for performing topography measurements of the experimental work pieces and providing pre-processed data for the PSD evaluations. Open access funding was provided by Vienna University of Technology (TU Wien).

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