Modeling and analysis of residual stresses of camshaft induced by swing grinding processes

Large grinding contact area tends to generate high grinding heat, resulting in the tolerance out of residual stress and influencing the service life of the camshaft. In the swing grinding process, a narrower grinding wheel makes pure rolling motion along the cam contour, and a periodic reciprocating motion along the sand wheel axis is utilized, which is conducive to reducing the grinding contact zone and diminishing the tolerance out problem of residual stress. However, the influence of swing grinding parameters on the residual stress variations of camshaft is not clear at present. In this study, the ABAQUS user subprograms of DFLUX and DLOAD were developed to simulate the grinding heat and the grinding force in swing grinding processes, and the residual stress finite element model under multi-field coupling was established to discuss the influence of process parameter on the residual stress distribution. The verification experiments were carried out by the X-ray diffraction method; the results showed that the simulation model is reasonable and reliable, and the error between the finite element model and the testing results is less than 16%. Increasing the swing frequency and swing amplitude can play an auxiliary role in the machining; the swing grinding can increase the residual compressive stress by at least 20.9% when compared with the ordinary plunge grinding. The residual stress in the camshaft after the swing grinding is linearly related to the initial residual stress before the grinding. The study can provide a reference for the parameter optimization of swing grinding process.