Study on the surface micro-topography in pre-stressed dry grinding process

To study the surface micro-topography in pre-stressed dry grinding process, the single grain cutting simulations were carried out in DEFORM-3D, besides, dry grinding experiments were conducted. The residual stress, groove depth and pile-up height were analysed in the simulations. The surface roughness was measured, and micro-surface topography was observed by SEM in the experiments. The results indicated that the application of pre-stress is beneficial to generate more compressive stress, which is beneficial to restrain the generation of surface micro-cracks. Pre-stress can reduce the pile-up height. When pre-stress is within a lower range, the groove depth decreases with pre-stress increasing, however, once pre-stress overcomes a certain value, surface fold appears and surface roughness increases instead. The influence rules of the cutting depth and feeding speed on surface micro-topography in pre-stressed dry grinding process are consistent with them in the traditional grinding process.