On the residual stress field induced by a scratching round abrasive grain

Most of superfinishing processes are based on the action of abrasive grains scratching the surface of a workpiece. These processes are known to improve the surface texture but they also modify the surface integrity, and thus the durability of engineering parts. In this paper, the residual stress field induced by the scratch of a single round abrasive grain is investigated by means of an implicit finite element analysis. First, it is shown that the residual stress profile is always modified over a depth of two or three times the contact radius, whatever the mechanical and physical properties. Second, key-parameters having a high influence on the tensile and compressive zone have been identified. They are the contact severity, the friction coefficient and the workpiece hardness. Third, it appears that the residual stress profile is not really affected by the presence of initial homogeneous residual stress field in the material. These results are then used to explain the experimental residual stress fields induced by a belt finishing process and a honing process on a AISI52100 hardened steel. Finally the possibility to design appropriate abrasive tools to improve both surface texture and surface integrity of manufactured parts is discussed.