Abstract: The machining process simulation of single grain with negative rake angle was performed by using the FEM software Deform-3D,and the rotating axial ultrasonic vibration surface grinding experiment device was designed and manufactured,which was used to carry out the experiment.The surface residual stress of 45 steel in different grinding conditions were measured respectively.It was found that the relative error was between 2.47% and 16.93%,which verified the correctness of the the finite element model of grinding surface residual stress.The simulation results show that:residual compressive stress is produced on the workpiece surface by generally and ultrasonic grinding,and the residual compressive stress in the axial direction is significantly greater than that in the grinding direction.The surface residual compressive stress increases with the increase of the amplitude,the grinding depth,the negative rake angle of the grain and the frequency of the ultrasonic vibration,and decreases with the increases of the speed of the grinding wheel.

Key words: residual stress, ultrasonic vibration grinding, single grain, process parameters, simulation