Experimental and numerical analysis of transient behavior during grind-hardening of AISI 52100

The grind-hardening process is an innovative approach to substitute conventional heat treatment processes. Due to the complex physical interrelationships and the lack of understanding regarding the process behavior and layout, extensive test series are required to assure reproducible hardening results. Therefore, methods for modeling and simulation are developed and used to analyze the thermo-metallurgical and thermo-mechanical effects during grind-hardening considering aspects like characteristics of process forces and tool wear. The objective of this paper is to predict the hardening depth distribution depending on the grinding path during grind-hardening in surface grinding by using finite-element-based simulations. Input data for the simulation are grinding forces, which are calculated by using regression analysis with respect to process parameters, e. g. specific removal rate Q′_w and equivalent grinding wheel diameter d_eq. The results of the simulation and the force model are validated by means of experiments. The consideration of the transient process behavior during grind-hardening within the developed models and simulations leads to an increase of process understanding and to new approaches regarding the efficient layout of the grind-hardening process.