When an alloy steel experiences a critical grinding condition, irreversible deformation caused by mechanical loading, thermal loading and micro-structural phase transformation couples with strong non-linearity. This paper presents an algorithm to analyze the residual stresses induced by the full coupling of all the above causes involving significant temperature- and microstructure-dependent property changes of workpiece materials. User-supplied subroutines to an existing FEM code were developed to simulate the coupled effect at the resolution of integration points. Results showed that the algorithm is quite efficient and stable in dealing with the non-linearity in grinding induced deformation.
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