THE EFFECT OF MECHANICAL AND GEOMETRIC CHARACTERISTICS OF INHOMOGENEOUS REGIONS ON THE INTENSITY OF CRACK FORMATION DURING THE GRINDING OF PARTS MADE OF FUNCTIONALLY-GRADIENT MATERIALS
DOI:
https://doi.org/10.20998/2078-7405.2026.104.06Keywords:
functionally graded materials, inhomogeneities, grinding, crack formationAbstract
The lack of research on the specifics of the initiation of grinding cracks and their development into main cracks depending on the design, technological, and structural inhomogeneities of the material of the products does not allow for the unambiguous application of existing recommendations for eliminating the defects in question. This work is devoted to investigating the influence of inherent inhomogeneities in the surface layer, their geometry, and mechanical characteristics in products made of functionally graded materials on the selection of technological conditions for defect-free machining of parts. It has been established that the magnitude of the stress intensity factors for inherent inhomogeneities formed in the surface layer of products made of functionally graded materials is influenced by the size and orientation of these defects, their depth of occurrence and mutual arrangement, and the magnitude of the heat flux during grinding. The geometry and properties of inclusions formed by previous operations in the surface layer can create conditions for both the inhibition and the development of grinding cracks. If the heat flux is directed parallel to the inclusion axis and a straight, thermally isolated crack, then when the linear thermal expansion coefficient of the inclusion is greater than that of the matrix, an increase in the stiffness of the inclusion leads to an increase in the stress intensity factors K_I (K_II=0) for various ratios of the thermal conductivity coefficients of the material components. This leads to the propagation of microcracks. Conversely, if the thermal expansion coefficient of the inclusion is lower than that of the matrix, a decrease in the stiffness of the inclusion leads to a decrease in the stress intensity factors K_I (K_II=0) for the same ratios of thermal conductivity coefficients, i.e., conditions favorable for the non-propagation of microcracks are present. Therefore, when determining defect-free grinding parameters, it is necessary, first and foremost, to establish the maximum permissible cutting depths. In doing so, it is also important to have information not only on the thermophysical and mechanical properties of the material and the presence of inhomogeneities in the surface layer, but also on its processing conditions.
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