A comparative study of hard turned and cylindrically ground white layers

Compared with grinding, hard turning is competitive in many cases, with substantial benefits. However, hard turning applications are not preferred, due to the existence of the process-induced white layer on the component surface, which is often assumed to be detrimental to component life. Nevertheless, white layer properties have not been well understood or clearly defined, especially the properties of the white layer induced in hard turning as against grinding. A clear understanding of white layer properties will provide a solid physics basis for product performance analysis and useful data for process selection. In this study, benchmark hard turning and cylindrical grinding experiments were conducted to generate thick white layers for reliable measurement. It was found that the properties of white and dark layers by hard turning and grinding are fundamentally different in four aspects: surface structure characteristics, microhardness, microstructures, and chemical composition. A white layer is not untempered martensite in terms of retained austenite. Additionally, a thick white layer can be produced in grinding under certain conditions.