轴向超声辅助端面磨削金属表面形貌及粗糙度预测

doi:10.3901/JME.2023.05.307

机械工程学报 ›› 2023, Vol. 59 ›› Issue (5): 307-316.doi: 10.3901/JME.2023.05.307

扫码分享

轴向超声辅助端面磨削金属表面形貌及粗糙度预测

张园, 徐念伟, 鲍岩, 董志刚, 韩松, 郭东明, 康仁科

大连理工大学精密与特种加工教育部重点实验室大连 116024

收稿日期:2022-03-11 修回日期:2022-09-16 出版日期:2023-03-05 发布日期:2023-04-20
通讯作者: 康仁科(通信作者),男,1962年出生,博士,教授,博士生导师。主要研究方向为超精密与特种加工技术、难加工材料高效加工技术、计算机辅助设计与制造技术。E-mail:kangrk@dlut.edu.cn
作者简介:张园,女,1992年出生,博士研究生。主要研究方向为超声振动辅助加工技术、金属材料加工表面完整性优化控制技术。E-mail:zyshuaiqi@mail.dlut.edu.cn
基金资助:
国家科技重大专项资助项目(2017-VII-0002-0095)。

Surface Topography and Roughness Prediction of Axial Ultrasonic Assisted Facing Grinding Metal

ZHANG Yuan, XU Nianwei, BAO Yan, DONG Zhigang, HAN Song, GUO Dongming, KANG Renke

Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian 116024

Received:2022-03-11 Revised:2022-09-16 Online:2023-03-05 Published:2023-04-20

摘要/Abstract

摘要： 轴向超声辅助端面磨削被广泛应用于难加工材料加工，而磨削后的表面粗糙度对构件摩擦、疲劳等服役性能有重要影响。超声振幅的大小对轴向超声辅助端面磨削金属表面形貌和粗糙度有较大影响，但是现有模型中并未考虑实际加载对振幅的影响，因此提出了一种考虑加载状态下振幅变化的轴向超声辅助端面磨削金属表面形貌及粗糙度预测方法。根据砂轮粒度及尺寸建立了考虑磨粒随机分布的砂轮端面模型，并对轴向超声辅助端面磨削磨粒的三维磨削轨迹进行了数学描述，生成了加工后的表面三维数据矩阵并对表面粗糙数值进行了计算。在此基础上，研究了粗糙度随振幅的变化规律，提出了振幅衰减形貌映射系数这一概念，并给出了其标定方法。通过振幅衰减形貌映射系数近似计算出加载状态下的振幅并代入到所建立的轴向超声辅助端面磨削表面形貌及粗糙度预测模型中，实现了金属表面形貌模拟及粗糙度预测。最后，通过试验对所建模型的正确性进行了验证。

关键词: 超声振动, 磨削, 超声振幅, 表面形貌, 表面粗糙度

Abstract: Axial ultrasonic assisted face grinding is widely used in difficult-to-machine material machining and the surface topography and roughness, which have significant influence on friction and fatigue properties. Ultrasonic vibration amplitude has a considerable influence on axial ultrasonic assisted facing grinding surface topography and roughness. In present surface topography and roughness prediction models, the influence of load on vibration amplitude has not been considered, so an axial ultrasonic assisted face grinding metal surface topography and roughness prediction model considering the variation of amplitude is proposed. A model of grinding wheel end face is built according to the wheel size and granularity. Three dimensional grinding trajectory is described mathematically. The three dimensional surface topography data and roughness of machined surface are calculated. On this basis, variation of surface roughness with ultrasonic vibration amplitude is investigated. Consequently, a concept of amplitude attenuation topography mapping coefficient is processed, and its calibration method is also given. Further, the amplitude with loaded could be calculated via the amplitude attenuation topography mapping coefficient. With the amplitude with loaded, the surface topography and roughness are gained with the axial ultrasonic assisted face grinding metal surface topography and roughness prediction model. Finally, accuracy of the prediction model is verified via axial ultrasonic assisted face grinding experiments.

Key words: ultrasonic vibration, grinding, amplitude, surface topography, surface roughness

中图分类号:

TG156

张园, 徐念伟, 鲍岩, 董志刚, 韩松, 郭东明, 康仁科. 轴向超声辅助端面磨削金属表面形貌及粗糙度预测[J]. 机械工程学报, 2023, 59(5): 307-316.

ZHANG Yuan, XU Nianwei, BAO Yan, DONG Zhigang, HAN Song, GUO Dongming, KANG Renke. Surface Topography and Roughness Prediction of Axial Ultrasonic Assisted Facing Grinding Metal[J]. Journal of Mechanical Engineering, 2023, 59(5): 307-316.

参考文献

[1] 徐瑞玲,赵波. 基于切向超声的平面磨削参数有效性研究[J]. 金刚石与磨料磨具工程,2015,32(6):32-36. XU Ruiling,ZHAO Bo. Study on effectiveness of plane grinding parameters based on tangential ultrasonic vibration[J]. Diamond & Abrasives Engineering,2015,32(6):32-36.
[2] 张嘉桐. 超声辅助磨削中振动方向对材料去除的影响[D]. 大连:大连理工大学,2018. ZHANG Jiatong. Study on the influence of ultrasonic vibration direction on material removal behavior in ultrasonic assisted grinding[D]. Dalian:Dalian University of Technology,2018.
[3] TAWAKOLI T,AZARHOUSHANG B. Influence of ultrasonic vibrations on dry grinding of soft steel[J]. International Journal of Machine Tools & Manufacture,2008,48(14):1585-1591.
[4] YAN Yanyan,ZHAO Bo,LIU Junli. Ultraprecision surface finishing of nano-ZrO₂ ceramics using two-dimensional ultrasonic assisted grinding[J]. International Journal of Advanced Manufacturing Technology,2009,43:462-467.
[5] GAO Guofu,ZHAO Bo,XIANG Daohui,et al. Research on the force characteristics in ultrasonic grinding nano-zirconia ceramics[C]//Advances in Machining & Manufacturing Technology IX. School of Mechanical and Power Engineering,Henan Polytechnic University,Jiaozuo,China; School of Mechanical Engineering,Tongji University,Shanghai,China,2008:258-262.
[6] WEN Xuelong,GONG Yadong,SUN Yao,et al. Experiment and finite element analysis research on surface roughness in micro-grinding H62[J]. Advanced Materials Research,2016,1136:21-29.
[7] YUAN Suoxian,XIAO Min. Experimental study on the mechanism of axial ultrasonic-assisted grinding[J]. Advanced Materials Research,2012,490-495:2449-2453.
[8] 郑非非. 空间反射镜材料的超声辅助磨削机理[D]. 大连:大连理工大学,2020. ZHENG Feifei. Ultrasonic assisted grinding mechanisms of space reflector materials[D]. Dalian:Dalian University of Technology,2020.
[9] 韩璐. GH4169高温合金超声辅助磨削表面完整性研究[D]. 大连:大连理工大学,2021. HAN Lu. Study on surface integrity in ultrasonic assisted grinding of GH4169 superalloy[D]. Dalian:Dalian University of Technology,2021.
[10] Lee B H,Keum Y T,Wagoner R H. Modeling of the friction caused by lubrication and surface roughness in sheet metal forming[J]. Journal of Materials Processing Technology,2002,130(2):60-63.
[11] Chieragatti M. Modelling the influence of machined surface roughness on the fatigue life of aluminium alloy[J]. International Journal of Fatigue,2008,30:2119-2126.
[12] 李盛超,王彦东,王雨时,等. 40Cr零件预应力淬硬磨削表面粗糙度值分析[J]. 金刚石与磨料磨具工程,2016,36(1):20-24. LI Shengchao,WANG Yandong,WANG Yushi,et al. Analysis on surface roughness in pre-stress hardening grinding process of 40Cr workpiece[J]. Diamond & Abrasives Engineering,2016,36(1):20-24.
[13] ZHOU Weihua,TANG Jinyuan,CHEN Haifeng,et al. A comprehensive investigation of surface generation and material removal[J]. International Journal of Mechanical Sciences,2019,156:14-43.
[14] YANG Zhichao,ZHU Lida,NI Chenbing,et al. Investigation of surface topography formation mechanism based on abrasive-workpiece contact rate model in tangential ultrasonic vibration-assisted CBN grinding of ZrO2 ceramics[J]. International Journal of Mechanical Sciences,2019,155:66-82.
[15] 陈海锋,唐进元,邓朝晖,等. 考虑耕犁的超声磨削表面微观形貌建模与预测[J]. 机械工程学报,2018,54(21):231-240. CHEN Haifeng,TANG Yuanjin,DENG Zhaohui,et al. Modeling and predicting surface topography of the ultrasonic assisted grinding process considering ploughing action[J]. Journal of Mechanical Engineering,2018,54(21):231-240.
[16] WEN Xuelong,GONG Yadong,SUN Yao,et al. Experiment and finite element analysis research on surface roughness in micro-grinding H62[J]. Advanced Materials Research,2016,1136:21-29.
[17] Hecker R L,Liang S Y. Predictive modeling of surface roughness in grinding[J]. International Journal of Machine Tools & Manufacture,2003,43(8):755-761.
[18] LU Hao,ZHU Lida,yang Zhichao,et al. Research on the generation mechanism and interference of surface texture in ultrasonic vibration assisted milling[J]. International Journal of Mechanical Sciences,2021,208(106681):1-18.
[19] CHEN Haifeng,TANG Jinyuan. A model for prediction of surface roughness in ultrasonic-assisted grinding[J]. International Journal of Advanced Manufacturing Technology,2015,77:643-651.
[20] CHEN Yurong,SU Honghua,QIAN Ning,et al. Ultrasonic vibration-assisted grinding of silicon carbide ceramics based on actual amplitude measurement:Grinding force and surface quality[J]. Ceramics International,2021,47(11):15434-15441.
[21] WEN Yuqin,TANG Jinyuan,ZHOU Wei,et al. Study on contact performance of ultrasonic-assisted grinding surface[J]. Ultrasonics,2019,91:193-200.
[22] ZHENG Feifei,KANG Renke,DONG Zhigang,et al. A theoretical and experimental investigation on ultrasonic assisted grinding from the single-grain aspect[J]. International Journal of Mechanical Sciences,2018,148:667-675.
[23] GAO Feng,ZHENG Feifei,DONG Zhigang,et al. Grinding force of RB-SiC in ultrasonic assisted grinding with sintered diamond grinding wheel[J]. Materials Science Forum,2016,861:56-62.
[24] 王健健. 陶瓷基复合/硬脆材料旋转超声制孔损伤机理与抑制策略[D]. 北京:清华大学,2017. WANG Jianjian. Damage formation mechanism and suppression methods in rotary ultrasonic drilling of hard and brittle materials & ceramic matrix composites[D]. Beijing:Tsinghua University,2017.
[25] XUN C,ROWE W B. Analysis and simulation of the grinding process. Part I:Generation of the grinding wheel surface[J]. International Journal of Machine Tools and Manufacture,1996,36(8):871-882.
[26] CHEN X,ROWE W B. Analysis and simulation of the grinding process. Part II:Mechanics of grinding[J]. International Journal of Machine Tools & Manufacture,1996,36(8):883-896.
[27] 段耀凯. 超精密切削微小结构表面的建模及分析[D]. 哈尔滨:哈尔滨工业大学,2006. DUAN Yaokai. The model and analysis of micro structure surface in ultra precision turning[D]. Harbin:Harbin Institute of Technology,2006.

轴向超声辅助端面磨削金属表面形貌及粗糙度预测

Surface Topography and Roughness Prediction of Axial Ultrasonic Assisted Facing Grinding Metal

PDF

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 15

编辑推荐

Metrics

本文评价

[1]	苏志朋, 梁志强, 李娟, 王飞, 魏正义, 刘月红, 金惟薇, 马悦, 殷振, 王西彬. 钛合金微槽超声螺线辅助铣磨加工试验研究[J]. 机械工程学报, 2024, 60(9): 5-12.
[2]	武韩强, 陈卓, 叶曦珉, 张诗博, 李偲偲, 曾江, 汪强, 吴勇波. 钛合金超声辅助等离子体氧化改性磨削基本加工特性研究[J]. 机械工程学报, 2024, 60(9): 13-25.
[3]	董志刚, 王中旺, 冉乙川, 鲍岩, 康仁科. 碳纤维增强陶瓷基复合材料超声振动辅助铣削加工技术的研究进展[J]. 机械工程学报, 2024, 60(9): 26-56.
[4]	殷振, 张坤, 戴晨伟, 程敬彩, 徐海龙, 李华. 超声椭圆振动磨削SiC陶瓷的砂轮磨损与磨削性能研究[J]. 机械工程学报, 2024, 60(9): 57-74.
[5]	梁奉爽, 吴明阳, 刘立飞. 基于材料冲击特性的碳化硅超声磨削机理及亚表面损伤特征研究[J]. 机械工程学报, 2024, 60(9): 75-85.
[6]	陈守峰, 王成勇, 李伟秋, 丁峰, 卢耀安, 周玉海. 超声振动铣削加工石墨材料去除机理与加工表面质量评价[J]. 机械工程学报, 2024, 60(9): 86-96.
[7]	周京国, 张宇航, 隋天一, 行登海, 董宝昆, 付清宇, 付俊帆, 林彬. 分离-接触特征对钛合金超声振动辅助铣削加工特性影响规律研究[J]. 机械工程学报, 2024, 60(9): 97-113.
[8]	吴淑晶, 王大中, 谷顾全, 黄帅, 董国军, 郭国强, 安庆龙, 李长河. 多种能场高性能加工复杂曲面关键技术研究进展[J]. 机械工程学报, 2024, 60(9): 152-167.
[9]	刘鑫, 张俊, 徐斌斌, 刘弘光, 赵万华. 激光辅助铣削过程的预热温度场调控方法研究[J]. 机械工程学报, 2024, 60(9): 218-228.
[10]	肖贵坚, 刘振扬, 贺毅, 刘岗, 邓忠才. 激光辅助CBN砂带磨削TC4钛合金材料去除行为及表面完整性研究[J]. 机械工程学报, 2024, 60(9): 241-253.
[11]	王晓铭, 李长河, 杨敏, 张彦彬, 刘明政, 高腾, 崔歆, 王大中, 曹华军, 陈云, 刘波. 纳米生物润滑剂微量润滑加工物理机制研究进展[J]. 机械工程学报, 2024, 60(9): 286-322.
[12]	崔歆, 李长河, 张彦彬, 杨敏, 周宗明, 刘波, 王春锦. 磁力牵引纳米润滑剂微量润滑磨削力模型与验证[J]. 机械工程学报, 2024, 60(9): 323-337.
[13]	关集俱, 祝正兵, 徐正亚, 栾志强, 许雪峰. CNTs@T321微囊制备的纳米流体与砂轮磨削时的双重润滑增效机制[J]. 机械工程学报, 2024, 60(9): 351-363.
[14]	何喆, 黄新春, 宋艺辉, 史耀耀, 张兆顷, 史恺宁. 服役温度影响的DD6单晶高温合金磨削/喷丸加工表面完整性演化规律研究[J]. 机械工程学报, 2024, 60(9): 410-420.
[15]	朱少禹, 张向军, 孙军, 王大刚. 粗糙表面轴承微极流体润滑的平均流量模型[J]. 机械工程学报, 2024, 60(7): 203-211.