Surface Integrity in the Grinding of Hardened AISI D2 Steel

The surface integrity of grinding has a significant influence on the service performance and life of machined parts. In this study, the influence of grinding parameters and the grit size of the grinding wheel on the surface integrity of the hardened steel, including the roughness, microstructure, and hardness of the subsurface and the residual stress of the ground surface, was comprehensively investigated, and the corresponding mechanisms were revealed. The results show that the roughness perpendicular to the grinding direction was significantly larger than that parallel to the grinding direction due to serious side flow, and increasing the grinding speed or reducing the grinding depth was beneficial for reducing the side flow and thus decreasing the roughness. It was found that the grinding temperature dominated the formation of a harder white layer and a softer black layer, and workpiece speed had the smallest effect on the transition of subsurface microstructure compared to grinding speed and depth. It was also found that the increase in workpiece speed, grinding depth, or grinding speed resulted in a transition from compressive to tensile residual stress or an increase in tensile residual stress, and that grinding wheels with finer grit tended to induce compressive residual stress. This study may help to improve surface integrity by optimizing grinding parameters or facilitating the selection of the optimal grinding wheel.