Abstract

This study investigates the influence of the spatial distribution of specific grinding power within the contact zone on subsurface layer modification and the resulting modification depth effects. In surface grinding experiments on AISI 4140, the width of cut and depth of cut were deliberately modified to generate distinct thermal loads within the grinding contact zone, with simultaneous measurement of tangential and normal grinding forces to quantify the mechanical loading conditions. The distribution of specific grinding power was analyzed with respect to its localization along the contact length and across the width of cut. The results indicate a predominantly uniform distribution of grinding power density within the contact zone under the investigated process conditions. Subsurface integrity was characterized in terms of tempering effects in metallographic cross-sections, hardness and residual stress depth profiles. These findings were correlated with Barkhausen noise measurements to establish a non-destructive assessment methodology for thermally induced modifications. Also, roughness measurements were evaluated. The experimental results reveal a consistent relationship between specific grinding power input and subsurface modification depth. Furthermore, a uniform grinding burn threshold was identified, indicating a critical condition for thermally induced surface damage.

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