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<p>AISI 4340 alloy steel is widely used in critical aerospace components due to its high strength, yet achieving superior surface integrity during high-efficiency grinding remains a challenge. This study systematically investigates the formation mechanisms of microscopic defects (including micro-cracks, pits, and regional burns) and their suppression strategies in high-speed grinding. Using a #100 grit CBN wheel, the evolution of surface roughness (Ra), micro-morphology, and residual stress was analyzed across a speed range of 40–150&#xa0;m/s. Results demonstrate that at <i>v</i><sub><i>s</i></sub> ≥100&#xa0;m/s, the material removal transitions to a stable regime where Ra stabilizes within 0.38–0.54&#xa0;μm. Residual stress analysis reveals a consistent compressive state, which is fundamentally governed by a synergistic thermomechanical balance: the “thermal lag effect” at ultra-high speeds restricts intense heat to a shallow surface layer, allowing mechanical reinforcement to dominate. Furthermore, the specialized fully synthetic fluid effectively suppresses Fe<sub>2</sub>O<sub>3</sub> oxidation by breaking the aerodynamic airflow barrier. Based on these mechanistic insights, an integrated control strategy (<i>v</i><sub><i>s</i></sub>&gt;100&#xa0;m/s, <i>f</i> ≤ 400&#xa0;mm/min) is proposed. This research provides a robust scientific basis for the precision grinding of high-strength alloys, ensuring defect-free surfaces while maintaining high removal efficiency.</p>

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Investigation on surface integrity and defect suppression mechanisms in high-speed grinding of AISI 4340 alloy steel

  • 期刊论文

  • 发表日期：

    2026年7月25日

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  • Yuxin Xie,
  • Mingquan Li,
  • Xinyan Hu,
  • Xiangyun Ni,
  • Genyu Chen

摘要

AISI 4340 alloy steel is widely used in critical aerospace components due to its high strength, yet achieving superior surface integrity during high-efficiency grinding remains a challenge. This study systematically investigates the formation mechanisms of microscopic defects (including micro-cracks, pits, and regional burns) and their suppression strategies in high-speed grinding. Using a #100 grit CBN wheel, the evolution of surface roughness (Ra), micro-morphology, and residual stress was analyzed across a speed range of 40–150 m/s. Results demonstrate that at vs ≥100 m/s, the material removal transitions to a stable regime where Ra stabilizes within 0.38–0.54 μm. Residual stress analysis reveals a consistent compressive state, which is fundamentally governed by a synergistic thermomechanical balance: the “thermal lag effect” at ultra-high speeds restricts intense heat to a shallow surface layer, allowing mechanical reinforcement to dominate. Furthermore, the specialized fully synthetic fluid effectively suppresses Fe2O3 oxidation by breaking the aerodynamic airflow barrier. Based on these mechanistic insights, an integrated control strategy (vs>100 m/s, f ≤ 400 mm/min) is proposed. This research provides a robust scientific basis for the precision grinding of high-strength alloys, ensuring defect-free surfaces while maintaining high removal efficiency.