(Dr. Tom Kurfess, advisor)

"A Finite Element Simulation of Thermally-Induced Residual Stresses in Grinding of Titanium Aluminide"

Abstract

Abrasive grinding is a machining process used to remove material and produce a desired surface geometry and finish.  Since grinding is typically used as a finishing operation, any damage inflicted on the workpiece during grinding may have an effect on the performance of the finished part.  Gamma titanium aluminide is an ordered intermetallic compound with a low ductility at ambient temperature, and is therefore relatively sensitive to the damage typically produced during the grinding process.  The purpose of this research is to develop a simplified finite element model capable of predicting thermally-induced residual stresses in grinding of g-TiAl under varied grinding conditions.  Such a model enables the prediction of temperature gradients and resulting residual stresses based on grinding input parameters.

A series of experiments were undertaken to measure changes in workpiece temperature during grinding of g-TiAl.  These measured temperatures were then compared to simulated results in order to evaluate the extent of validity of the model.