Process Parameters and Residual Stresses in Cylindrical Grinding

The paper presents an experimental study on the relationship between process parameters and residual stresses in cylindrical grinding. In particular, the influence of the depth of cut (a) and the peripheral velocity of the workpiece $vw$ was investigated. Residual stresses were found to depend on both parameters, but the effect of the peripherial velocity depends on the grinding conditions. In “easy to grind” conditions an increase in workpiece velocity leads to an increase in residual stresses, but in “difficult to grind” conditions an increase in workpiece velocity results in a decrease in residual stresses. Consequently, two joint parameters, $Zw=as˙vw,$ and $Kw=a/vw,$ were used to predict residual stresses. Regression analysis was then performed to determine the analytic relationship between the joint parameters and the residual stresses in “easy” and “difficult” grinding conditions. Finally, the influence of wheel wear, feed rate, sparkout and wheel dressing was investigated. The study showed that the workpiece feed rate does not seem to influence the residual stresses, while sparkout, wheel wear, and wheel dressing significantly affect the level of residual stresses generated during machining.