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Stainless Steel Products Presents FATIGUE LIFE IMPROVEMENTS OF GROUND SURFACES BY WIRE BRUSHING Grinding of Surfaces Causes Microchip Buildup Surface Burning Material Redeposition Surface & Subsurface Cracking Mechanical & Metallurgical Transformation

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stainless steel products presents
Stainless Steel Products Presents

FATIGUE LIFE IMPROVEMENTS

OF GROUND SURFACES

BY WIRE BRUSHING

grinding of surfaces causes microchip buildup
Grinding of Surfaces Causes Microchip Buildup
  • Surface Burning
  • Material Redeposition
  • Surface & Subsurface Cracking
  • Mechanical & Metallurgical Transformation
  • Surface Tensile Residual Stresses
remedies to minimize the effects of grinding and improve compressive residual stresses
Fine Grinding

Low Work Speeds

Small Cut Depths

CBN or Diamond Grit

Polishing

Shot Peening

Ball Burnishing

Surface Coating/Nitriding

Remedies to Minimize the Effects of Grinding and Improve Compressive Residual Stresses
wire brushing
Wire Brushing
  • Fast and Easy
  • A Low Cost Alternative
  • Common for On-Line Polishing/Deburring
  • Good for Complex Geometries
  • Induces Hardening and Compressive Residual Stresses
purpose of experiments
Purpose of Experiments
  • Measure Fatigue Life Enhancements on Stainless Steel Ground Surfaces Using Wire Brushing

o Optimized Brushing Conditions criteria related to

=>Residual Stresses

=> Work Hardening

=> Surface Roughness

=> Burr Formation

  • Investigate mechanisms of fatigue crack initiation and propagation
  • Establish the role of work hardening and residual stress on fatigue crack growth
experimental procedures
Experimental Procedures
  • Material: 304 Stainless Steel
  • Ground Surface: “V” shaped notched bar
  • Only the Notch was Ground or Brushed
  • Test Surfaces characterized by measuring roughness
  • Hardening characterized by microhardness measurements
  • Residual Stresses were evaluated using X-Ray methods
  • High Cycle Fatigue Tests used a 3 point bend geometry
  • Other effects measured include surface finish, and surface temperature
electron microscopy
Electron Microscopy

Ground Surface

1000x

Brushed Surface

2000x

summary of wire brushing benefits
Summary of Wire Brushing Benefits
  • Relatively Inexpensive and Simple Process
  • Fatigue Life Improvements resulting from

o Peak & valley reductions on ground surfaces resulting in

fewer potential sites for fatigue crack initiation

  • Work Hardening Effects resulting from

o Higher surface hardening and deeper work hardened layer

  • Eliminates Thermal Micro cracks by:

o Removing the thermally effected layer induced by grinding

  • Results in Higher Compressive Residual Stresses by:

o Generating higher micro geometrical qualities and hardness

  • Higher Geometrical Qualities vs. Shotpeening with Similar Compressive Residual Stresses
references
References

Presented by: Ralph Rosenbaum

Stainless Steel Products

561-T Acorn Street, Deer Park, NY 11729

Phone (888) 767-3040

Fax: (631) 243-1500

E-mail: Ralph@STAINLESSWIRES.COM

Article By: Nabil Ben Fredj, Mohamed Ben Nasr, Amir Ben Rhouma, Chedly Braham, and Habib Sidhom, Fatigue Life Improvements of the AISI 304 Stainless Steel Ground Surfaces by Wire Brushing, ASM International 1059-9495, December 21, 2003, p 564-574

Article Web link: http://www.springerlink.com/content/b824020760543lg0/