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<p>Residual stress and solid-state phase transformations are commonly induced by mechanical and thermal loading in the micro-grinding of multi-phase materials. Tensile residual stresses are detrimental to the mechanical properties and fatigue life of high-precision components. Conversely, the transformation from austenite to martensite enhances the strength of the machined parts. The dynamic evolution mechanism of microstructure and its effect on residual stress during micro-grinding remains a subject of study. This paper aims to optimize process parameters and material texture to minimize residual stress and maximize martensite transformation. Analytical models for residual stress are proposed, considering both process parameters and material texture, and are validated with experimental data. A Hybrid Weighting Method (HWM), based on an orthogonal experimental design, is employed to determine optimal process parameters, leveraging the prediction results of residual stress and martensite transformation. The optimized results reveal that the minimum residual stress and maximum martensite transformation occur with a surface speed of 1.57&#xa0;m/s, a feed rate of 5&#xa0;mm/min, a depth of cut of 2&#xa0;μm, and a Taylor factor of 2.078.</p>

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Multi-objective parametric optimization of process parameters and material texture for minimum surface residual stress and maximum martensite transformation in micro-grinding based on analytical model

  • 期刊论文

  • 发表日期：

    2026年7月4日

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  • Yalong Zhang,
  • Jian Song,
  • Shengyu Qiu,
  • Man Zhao

摘要

Residual stress and solid-state phase transformations are commonly induced by mechanical and thermal loading in the micro-grinding of multi-phase materials. Tensile residual stresses are detrimental to the mechanical properties and fatigue life of high-precision components. Conversely, the transformation from austenite to martensite enhances the strength of the machined parts. The dynamic evolution mechanism of microstructure and its effect on residual stress during micro-grinding remains a subject of study. This paper aims to optimize process parameters and material texture to minimize residual stress and maximize martensite transformation. Analytical models for residual stress are proposed, considering both process parameters and material texture, and are validated with experimental data. A Hybrid Weighting Method (HWM), based on an orthogonal experimental design, is employed to determine optimal process parameters, leveraging the prediction results of residual stress and martensite transformation. The optimized results reveal that the minimum residual stress and maximum martensite transformation occur with a surface speed of 1.57 m/s, a feed rate of 5 mm/min, a depth of cut of 2 μm, and a Taylor factor of 2.078.