粗金刚石砂轮的超声辅助机械化学修整机理与镜面磨削应用

doi:10.3901/JME.2025.17.381

摘要/Abstract

摘要： 粗金刚石砂轮可以实现硬脆材料的高效磨削加工，但其磨削质量较差，且修整效率极低，提出采用超声辅助机械化学修整方法对粗金刚石砂轮进行高效精密修整，获得磨粒出刃型面等齐的金刚石砂轮，实现碳化硅陶瓷硬脆材料的高效精密镜面磨削加工。超声辅助机械化学修整是利用金刚石与铸铁修整工具之间的超声高频摩擦振动和原子亲和化学催化作用快速将金刚石石墨化去除，实现金刚石砂轮的高效精密修整。首先，研究超声功率、修整压力、修整时间等超声修整工艺参数对#80粗金刚石磨粒出刃等齐性的影响；然后，对比分析超声辅助机械化学修整参数和磨削工艺参数对碳化硅陶瓷磨削表面质量的影响。实验结果表明：采用超声辅助机械化学修整工艺可以有效提高砂轮磨粒出刃等齐性，当超声功率、修整压力和修整时间分别为80%、80 N和120 s时，磨粒出刃高度集中在96～135 μm区间内的磨粒数占比从69.8%(修整前)增加至92.1%。与传统机械修整相比，采用超声辅助修整后的金刚石砂轮具有更好的磨削性能，可降低碳化硅表面粗糙度约84.6%。当砂轮转速N=18 000 r/min，进给速度v_f=10 mm/min，磨削深度a_p=1 μm时，碳化硅宏观磨削表面呈现镜面效果，其表面粗糙度R_a可达46 nm。

关键词: 粗金刚石砂轮, 超声, 修整, 等齐性, 镜面磨削, 碳化硅

Abstract: The coarse diamond grinding wheel can realize the high-efficiency grinding processing of hard and brittle materials, but its grinding quality is poor, and the truing efficiency is extremely low. The ultrasonic assisted mechanical-chemical truing method is proposed to carry out high efficiency and precision truing for coarse diamond grinding wheel to obtain the truncated protrusive micro grain cutting edges, performing the high efficiency and precision mirror grinding processing of hard and brittle materials of silicon carbide ceramics. Ultrasonic assisted mechanical-chemical truing utilizes the ultrasonic high-frequency friction vibration between diamond and cast iron truing tools and atomic affinity chemical catalytic effect to rapidly remove graphited diamond to realize the efficient precision truing of coarse diamond grinding wheel. Firstly, the influences of ultrasonic truing process parameters including ultrasonic power, truing pressure and truing time on the protrusion homogeneity of #80 coarse diamond grains are investigated; then, the effects of the ultrasonic assisted mechanic-chemical truing parameters and grinding process parameters on the ground surface quality of silicon carbide ceramic are comparatively analyzed. The experimental results show that the ultrasonic assisted mechanic-chemical truing can effectively improve the grain protrusion homogeneity of grinding wheel, and when the ultrasound power, truing pressure, and truing time are 80%, 80 N, and 120 s, respectively, the percentage of the grains with protrusion height ranged from 96～135 μm increases from 69.8% (before truing) to 92.1%. Compared with the traditional mechanical truing, the diamond grinding wheel after ultrasonic assisted truing has better grinding performance and can reduce the surface roughness of silicon carbide by about 84.6%. When the rotational speed N=18 000 r/min, feed speed v_f=10 mm/min, grinding depth a_p=1 μm, the macroscopic ground surface of silicon carbide presents a mirror effect, and its surface roughness R_a can reach 46 nm.

Key words: coarse diamond grinding wheel, ultrasonic, truing, homogeneity, mirror grinding, silicon carbide

中图分类号:

TG74

鲁艳军, 杜嘉轩, 汪强, 关伟锋, 吴勇波. 粗金刚石砂轮的超声辅助机械化学修整机理与镜面磨削应用[J]. 机械工程学报, 2025, 61(17): 381-392.

LU Yanjun, DU Jiaxuan, WANG Qiang, GUAN Weifeng, WU Yongbo. Ultrasonic Assisted Mechanical-chemical Truing Mechanism of Coarse Diamond Grinding Wheel and Applications of Mirror Grinding[J]. Journal of Mechanical Engineering, 2025, 61(17): 381-392.

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