Abstract: Metallic material 12CrNi4A is a high-strength alloy steel, residual stress calculation of 12CrNi4A material in axial ultrasonic dry grinding (UDG) is researched. A new non-Gaussian heat source model is constructed by using the inverse heat method, and the temperature field distribution of 12CrNi4A under ultrasonic grinding process is calculated based on the finite element software COMSOL. The temperature history and distribution of ultrasonic grinding are measured by embedded thermocouple method. The finite element calculation is compared with the measured results, and the temperature error of grinding zone is within 5%. Considering the kinematic hardening function, coupling grinding thermal and grinding force of UAG, using finite method calculation ultrasonic grinding (UAG) surface residual stress distribution, compared with the measured values with X-ray, the error is within 10%. The results show that:1) ultrasonic grinding can effectively reduce the tensile residual stress cause by grinding heat and increase the residual compressive stress; 2) ultrasonic grinding can effectively reduce the maximum temperature in grinding zone and the reduction value equal to 24.1%. Based on the method of theoretical calculation and experiment, this paper predicts the residual stress of ultrasonic dry grinding is providing a reference for the in-depth study on ultrasonic grinding.

Key words: kinematic hardening, measurement of grinding temperature, simulation residual stress of ultrasonic grinding, ultrasonic grinding