砂轮磨削区气-液流场特性及调控技术研究进展

doi:10.3901/JME.260701

摘要/Abstract

摘要： 磨削作为精密制造领域的关键工艺，长期面临磨削高温易诱发工件热损伤的瓶颈。受气障效应制约，传统冷却工艺仅能实现20%～40%的冷却液有效利用率，导致“高耗低效”与环境污染的双重困境。系统梳理了砂轮-工件接触区流场的基本原理和研究进展，重点论述了供给装置设计、结构化砂轮设计及磨削工艺优化三类流场主动调控策略的最新突破：相较于常规喷嘴，实心喷嘴或3D打印喷嘴可使材料去除率提升近30%、冷却液消耗降低约70%；结构化砂轮通过导流结构与离心力-压力差耦合机制，可实现磨削区有效流量最高提升近3倍、磨削温度最大降幅达50 ℃；相较于纯气动雾化技术，气动-静电协同雾化技术可将PM10和PM2.5颗粒排放浓度分别降低约80%和90%。指出当前研究亟待突破气-液-热多物理场耦合建模精度不足、极端工况下微纳尺度润滑机制缺失两大瓶颈。未来研究应着重突破多物理场协同调控理论，重点开展磁场-电场-超声复合场作用下气液界面动力学研究，创新开发融合数字孪生与深度学习的智能磨削优化系统，构建面向极端制造条件的动态流场调控体系，并发展跨尺度热-力耦合能量回收技术，推动精密磨削向超低耗-超高效-零排放的制造范式演进。

关键词: 磨削, 气障效应, 气-液流场, 流场调控, 润滑, 冷却

Abstract: As a key process in the field of precision manufacturing, grinding has long faced the bottleneck of high grinding temperatures that easily induce thermal damage to workpieces. Due to the constraints of the gas barrier effect, the traditional cooling process can only achieve an effective utilization rate of 20%～40% of the coolant, resulting in the dual dilemma of high consumption, low efficiency and environmental pollution. The basic principles and research progress of the flow field in the contact area between the grinding wheel and the workpiece are systematically sorted out, and the latest breakthroughs in the three types of active flow field control strategies, namely, supply device design, structured grinding wheel design, and grinding process optimization, are discussed in detail. Compared with conventional nozzles, solid nozzles or 3D printing nozzles can increase material removal rates by nearly 30% and reduce coolant consumption by about 70%. Through the flow-guiding structure and the centrifugal force-pressure difference coupling mechanism, the structured grinding wheel can increase the effective flow rate in the grinding area by nearly 3 times and reduce the grinding temperature by up to 50 ℃. Compared with pure pneumatic atomization technology, pneumatic-electrostatic synergistic atomization technology can reduce the emission concentrations of PM10 and PM2.5 particles by approximately 80% and 90% respectively. It is pointed out that the current research urgently needs to break through the two bottlenecks of insufficient modeling accuracy of gas-liquid-heat multi-physics field coupling and lack of micro-nanoscale lubrication mechanism under extreme working conditions. Future research should focus on breaking through the theory of coordinated control of multiple physical fields, focusing on the study of gas-liquid interface dynamics under the action of magnetic field, electric field and ultrasonic composite field, innovatively developing an intelligent grinding optimization system integrating digital twins and deep learning, building a dynamic flow field control system for extreme manufacturing conditions, and developing cross-scale thermal-mechanical coupling energy recovery technology, so as to promote the evolution of precision grinding towards an ultra-low consumption, ultra-high efficiency and zero emission manufacturing paradigm.

Key words: grinding, air barrier effect, gas-liquid flow field, flow field regulation, lubrication, cooling

中图分类号:

TG580

邓辉, 王谦, 邓朝晖, 易军. 砂轮磨削区气-液流场特性及调控技术研究进展[J]. 机械工程学报, 2026, 62(13): 363-385.

DENG Hui, WANG Qian, DENG Zhaohui, YI Jun. Research Progress on the Characteristics and Regulation Technique of Gas-liquid Flow Field in Grinding Zone of Grinding Wheel[J]. Journal of Mechanical Engineering, 2026, 62(13): 363-385.

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链接本文: http://www.cjmenet.com.cn/CN/10.3901/JME.260701

http://www.cjmenet.com.cn/CN/Y2026/V62/I13/363

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