Residual stress generation in grinding: Mechanism and modeling

Residual stress, a pivotal indicator for assessing surface quality, represents significant thermomechanical stresses encountered during material removal processes. The precision of machining and workpiece performance is of paramount importance in the industries such as aerospace and tool manufacturing. Besides the mitigating residual stresses, the persistent challenge particularly lies in grinding operations. While the mechanisms of grinding-induced residual stresses deserve attention. This paper seeks to bridge this knowledge gap by conducting a thorough analysis of the factors contributing to residual stress generation, taking into account the characteristics of mechanical, thermal, and thermodynamic coupling stresses. Firstly, an exploration of the mechanisms behind residual stress generation leads to a deeper understanding of the factors initiating these stresses. Additionally, this analysis provides insights into auxiliary accuracy adjustment methods for integrated models. Subsequently, the microstructural mechanisms and stress modeling of typical materials are discussed when subjected to the combined effects of heat, force, and their coupling effect. Moreover, common detection techniques for real-time analysis and prediction are summarized. Notably, the resulting combined prediction models indicate an error range in residual stress prediction spanning from 3% to 6%, with an average error of approximately 3%. Finally, the principles governing residual stress generation find practical application in actual production scenarios, wherein different perspectives of ultra-precision grinding processes are considered. These findings not only enhance our comprehension and control of residual stresses but also establish a robust foundation for future advancements in this field.