粗粒度金刚石砂轮的放电赋能磨削修整试验研究

doi:10.3969/j.issn.1004-132X.2024.10.006

摘要/Abstract

摘要： 针对粗粒度金刚石砂轮磨粒出刃形貌难以控制的问题，提出了放电赋能磨削修整技术，旨在实现出刃磨粒的等齐性。系统研究了该复合修整技术的材料去除机理，建立脉冲放电传热数值模型，以金刚石热软化深度作为磨削深度，最大限度发挥放电赋能磨削的修整优势。探究了机床运动参数（待修砂轮转速、刀具轮转速、进给速度、磨削深度）对砂轮修整精度和刀具轮损耗深度的影响规律，并优化了工艺参数以实现粗粒度砂轮的高效高精修整。磨粒粒度为180目的金刚石砂轮修整后轮廓误差PV值为11.97 μm。修整砂轮表面形貌检测结果表明，放电赋能磨削修整可将磨粒部分去除，使得砂轮表面磨粒具有较好的等齐性。磨削的碳化硅陶瓷工件表面粗糙度达412 nm，表明了修整砂轮具有优异的磨削性能。

关键词: 放电赋能磨削, 金刚石砂轮, 砂轮修整, 轮廓精度

Abstract: The problems of difficult to control the morphology of abrasive grains on coarse-grained diamond grinding wheels were presented. A discharge aided grinding dressing technology was proposed to achieve the uniformity of abrasive grains on the cutting edges. The material removal mechanism of this hybrid dressing was systematically analyzed. The numerical models of pulse discharge heat transfer were established, and the thermal softening depth of diamond was used as the grinding depth, which was conducive to the advantages of the hybrid dressing method. The influences of machine tool kinematic parameters (such as the speed of the grinding wheel, the speed of the tool wheel, the feed speed, and the grinding depth) on the grinding wheel dressing accuracy and the loss depth of tool wheel in the discharge aided grinding dressing method were investigated, and the processing parameters were optimized to achieve high efficiency and precision dressing of coarse-grained grinding wheels. The profile error PV value of the diamond grinding wheels with a grain size of 180# is as 11.97 μm. The inspection results of the surface morphology of the dressing wheel indicate that discharge powered grinding may partially remove the abrasive particles, resulting in good homogeneity of the abrasive particles on the surfaces of the grinding wheel. The surface roughness of the ground silicon carbide ceramic workpiece reaches 412 nm, indicating that the dressing wheel has excellent grinding performance.

Key words: discharge aided grinding, diamond wheel, grinding wheel dressing, profile accuracy

中图分类号:

TG661

戴隆州1, 毛聪1, 张明军1, 陈根余2. 粗粒度金刚石砂轮的放电赋能磨削修整试验研究[J]. 中国机械工程, 2024, 35(10): 1762-1773.

DAI Longzhou1, MAO Cong1, ZHANG Mingjun1, CHEN Genyu2. Experimental Investigation of Discharge Aided Grinding Dressing Method of Coarse-grained Diamond Wheels[J]. China Mechanical Engineering, 2024, 35(10): 1762-1773.

导出引用管理器 EndNote|Ris|BibTeX

链接本文: http://www.cmemo.org.cn/CN/10.3969/j.issn.1004-132X.2024.10.006

http://www.cmemo.org.cn/CN/Y2024/V35/I10/1762

参考文献

［1］徐九华, 张志伟, 傅玉灿. 镍基高温合金高效成型磨削的研究进展与展望［J］. 航空学报, 2014, 35(2):351-360.
XU Jiuhua, ZHANG Zhiwei, FU Yucan. Review and Prospect on High Efficiency Profile Grinding of Nickel-based Superalloys［J］. Acta Aeronautica et Astronautica Sinica, 2014, 35(2):351-360.
［2］丁文锋, 苗情, 李本凯, 等. 面向航空发动机的镍基合金磨削技术研究进展［J］. 机械工程学报, 2019, 55(1):189-215.
DING Wengfeng, MIAO Qing, LI Bengkai, et al. Review on Grinding Technology of Nickel-based Superalloys Used for Aero-engine［J］. Journal of Mechanical Engineering, 2019, 55(1):189-215.
［3］郭兵, 金钱余, 赵清亮, 等. 表面结构化砂轮磨削加工技术研究进展［J］. 哈尔滨工业大学学报, 2016, 48(7):1-13.
GUO Bing, JIN Qianyu, ZHAO Qingliang, et al. Research Progress of Grinding Technology with Surface Structured Wheels［J］. Journal of Harbin Institute of Technology, 2016, 48(7):1-13.
［4］陈根余，戴隆州，李明全，等. 激光与电火花复合修整粗粒度弧形金刚石砂轮试验研究［J］. 中国机械工程, 2022, 33(15):1780-1786.
CHEN Genyu, DAI Longzhou, LI Mingquan, et al. Experimental Research on Coarse-grained Arc Diamond Grinding Wheel Dressed by Laser Dressing and Electrical Discharge Dressing［J］. China Mechanical Engineering，2022，33(15):1780-1786.
［5］袁尚勇，陈根余，戴隆州，等. 电火花机械磨削修整粗粒度成形砂轮试验研究［J］. 中国机械工程, 2023, 34(10):1164-1171.
YUAN Shangyong, CHEN Genyu, DAI Longzhou, et al. Experimental Research on Coarse-grained Forming Grinding Wheel Dressed by Electrical Discharge Diamond Grinding［J］. China Mechanical Engineering, 2023, 34(10):1164-1171.
［6］赵清亮, 赵玲玲, 王宇,等. 电镀金刚石砂轮高效精密修整及熔融石英磨削试验研究［J］. 机械工程学报, 2013, 49(23):174-181.
ZHAO Qingliang, ZHAO Lingling, WANG Yu, et al. High Efficient Precision Conditioning of the Electroplated Diamond Wheel and Grinding of Fused Silica Glasses［J］. Journal of Mechanical Engineering, 2013, 49(23):174-181.
［7］PALMER J, GHADBEIGI H, NOVOVIC D, et al. An Experimental Study of the Effects of Dressing Parameters on the Topography of Grinding Wheels during Roller Dressing［J］. Journal of Manufacturing Processes, 2018, 31(Supplement C):348-355.
［8］YAO Z, XU J, LU Z. Research on GC Cup Truing Technology of Super-hard Grinding Wheel［J］. Key Engineering Materials, 2018, 764:408-515.
［9］WARHANEK M, WALTER C, HUBER S, et al. Cutting Characteristics of Electroplated Diamond Tools with Laser-generated Positive Clearance［J］. CIRP Annals—Manufacturing Technology, 2015, 64(1):317-320.
［10］ACKERL N, WARHANEK M, GYSEL J, et al. Ultra-short Pulsed Laser Conditioning of Metallic Bonded Diamond Grinding Tools［J］. Materials & Design, 2020, 189:108530.
［11］CAI S, CHEN GY, ZHOU C, et al. Research and Application of Surface Heat Treatment for Multipulse Laser Ablation of Materials［J］. Applied Surface Science, 2015, 355:461-472.
［12］WANG Y Y, CHEN G Y, HU B, et al. An Experimental Study on the Picosecond Laser Dressing of Bronze-bonded Diamond Wheels［J］. Advances in Nano Research, 2022, 12(6):583-592.
［13］DENG H, XU Z. Laser-dressing Topography and Quality of Resin-bonded Diamond Grinding Wheels［J］. Optics and Lasers in Engineering, 2021, 136:106322.
［14］余剑武, 何利华, 尚振涛, 等. 小直径青铜结合剂微粉砂轮的电火花精密修整试验研究［J］. 机械工程学报, 2019, 55(3):199-207.
YU Jianwu, HE Lihua, SHANG Zhentao, et al. Experimental Investigation on Precision Electrical Discharge Dressing of Small-diameter Bronze-bonded Fine Grain Grinding Wheel［J］. Journal of Mechanical Engineering, 2019, 55(3):199-207.
［15］YAN J Y, LI S C, YANG Z, et al. Feasibility Study on Sharpening Metal-bond Metal Diamond Grinding Tool by Microwave-induced Electric Discharge Machining［J］. Ceramics International, 2023, 49:8952-8961.
［16］LU Y J, SUN J J, WU X Y, et al. On-Line Prediction of Impulse Spark and Arc Discharge Removals of Metal Bond in Dry Electrical Discharge Dressing of Diamond Grinding Wheel［J］. International Journal of Precision Engineering and Manufacturing-Green Technology, 2022, 10(2):293-310.
［17］BRINKSMEIER E, MUTLUGUNES Y, KLOCKE F, Ultra-precision Grinding［J］. CIRP Annals—Manufacturing Technology, 2010, 59:652-671.
［18］WANG Y, ZHOU X J, HU D J. An Experimental Investigation of Dry-electrical Discharge Assisted Truing and Dressing of Metal Bonded Diamond Wheel［J］. International Journal of Machine Tools & Manufacture, 2006, 46:333-342.
［19］MALKIN S, HWANG T W. Grinding Mechanisms for Ceramics［J］. CIRP Annals—Manufacturing Technology, 1996, 45(2):569-580.
［20］TAMURA T, KOBAYASHI Y. Measurement of Impulsive Forces and Crater Formation in Impulse Discharge［J］. Journal of Materials Processing Technology, 2004, 149:212-216.
［21］XIA H, HASHIMOTO H, KUNIEDA M, et al. Measurement of Energy Distribution in Continuous EDM Process［J］. Journal of the Japan Society for Precision Engineering, 1996, 62(8):1141-1145.
［22］REBELO J C, DIAS A M, MESQUITA R, et al. An Experimental Study on Electro-discharge Machining and Polishing of High Strength Copper-beryllium Alloys［J］. Journal of Materials Processing Technology, 2000, 103:389-397.
［23］HE Q, XIE J, LU K, et al. Study on In-air Electro-contact Discharge(ECD) Truncating of Coarse Diamond Grinding Wheel for the Dry Smooth Grinding of Hardened Steel［J］. Journal of Materials Processing Technology, 2020, 276:116402.
［24］DENG H, XU Z. Laser Dressing of Arc-shaped Resin-bonded Diamond Grinding Wheels［J］. Journal of Materials Processing Technology, 2021, 288:116884.
［25］DENG H, HE J. A Study of the Grinding Performance of Laser Micro-structured Coarse-grained Diamond Grinding Wheels［J］. International Journal of Advanced Manufacturing Technology, 2017, 93:1989-1997.

[1]	陈冰1, 卿光烨1, 郭烨1, 邓朝晖2. 弧形金刚石砂轮机械修整研究进展[J]. 中国机械工程, 2024, 35(08): 1331-1347.
[2]	袁尚勇, 陈根余, 戴隆州, 鲁恩昊. 电火花机械磨削修整粗粒度成形砂轮试验研究[J]. 中国机械工程, 2023, 34(10): 1164-1171.
[3]	鲁艳军, 关伟锋, 孙佳劲, 莫睿, 伍晓宇. 基于放电修锐的粗金刚石砂轮干式镜面磨削技术[J]. 中国机械工程, 2023, 34(09): 1052-1060.
[4]	李守港, 刘鹏, 刘祥, 胡志力, . 高强钢热冲压结构件三维激光切割回弹规律及精度补偿方法[J]. 中国机械工程, 2022, 33(22): 2741-2747.
[5]	陈根余, 戴隆州, 李明全, 袁尚勇. 激光与电火花复合修整粗粒度弧形金刚石砂轮试验研究[J]. 中国机械工程, 2022, 33(15): 1780-1786.
[6]	张鹏, 曹泽泽, 寇淑清, 王涛, 郭继保, 李金哲, 吴磊. 组合式凸轮轴径向滚花装配机理及连接强度研究[J]. 中国机械工程, 2022, 33(06): 664-671.
[7]	崔仲鸣；王星；赫青山；周宝仓. 金刚石型面约束的自由磨粒挤磨修整超硬磨料砂轮方法[J]. 中国机械工程, 2020, 31(24): 2959-2965.
[8]	李颂华1,2;韩涛1;王维东1;孙健1;韩光田1. 垂直式超硬砂轮圆弧修整器设计与砂轮修整[J]. 中国机械工程, 2020, 31(05): 513-518,526.
[9]	伍俏平, 邓朝晖, 赵前程, 潘占, 康辉民, 万林林, . 基于新型金刚石砂轮的Al2O3陶瓷磨削性能[J]. 中国机械工程, 2014, 25(16): 2240-2246.
[10]	张贝, 傅玉灿, 苏宏华. 单层钎焊金刚石砂轮的修整实验研究[J]. 中国机械工程, 2014, 25(13): 1778-1783.
[11]	陈建毅1, 徐西鹏2. 钎焊金刚石砂轮高速磨削氧化铝的磨削比能研究[J]. 中国机械工程, 2013, 24(07): 890-894.
[12]	王振忠1, 郭隐彪1, 李洁2, 雷向阳2, 张东旭1. 大口径光学元件高精度平面磨床加工系统研究 [J]. 中国机械工程, 2012, 23(1): 78-84.
[13]	詹友基, 李远, 黄辉, 徐西鹏. 钎焊金刚石砂轮磨削硬质合金的磨削力研究 [J]. 中国机械工程, 2010, 21(15): 1844-1849.
[14]	蔡兰蓉;贾妍;胡德金;. 电火花修整金刚石导电砂轮温度场分析和实验研究[J]. J4, 2008, 19(9): 0-1054.
[15]	王续跃;徐云飞;徐文骥;王连吉;康仁科;郭东明. 辅助侧向吹气法金刚石砂轮激光修锐试验与评价[J]. J4, 2008, 19(6): 0-750.