School of Mechanical Engineering, Jiangsu University of Technology, Changzhou 213001, China.
School of Mechanical Engineering, Jiangsu University of Technology, Changzhou 213001, China.
Ultrasonics. 2022 Jan;118:106577. doi: 10.1016/j.ultras.2021.106577. Epub 2021 Sep 9.
Ultrasonic assisted grinding (UAG) is a promising manufacturing technology in processing hard and brittle materials, mostly due to its excellent machining performance. In UAG, improvements in grain trajectory interactions and overlapping stemming from kinematic characteristics were identified as the main reasons for reduced grinding forces and improved processing quality. However, in existing studies, the grinding wheels with disordered abrasive grain distributions and irregular grain protrusion heights were generally used. Consequently, it is difficult to control both the interactions between grain trajectories and overlapping. Aiming to solve this problem, a brazed diamond grinding wheel with defined grain distribution was proposed in this study. The grinding wheel matrix was designed using finite element analysis, while abrasive grain distribution was obtained by kinematic analysis of UAG. Finally, the grinding wheel was prepared using brazing technology and to verify its grinding performance, an electroplated grinding wheel with the identic matrix and abrasive grain size was prepared. Morphology analysis of both grinding wheels has shown that compared to the electroplated grinding wheel, the brazed one has both higher and more uniform grain protrusion height. In the next step, UAG and CG experiments were carried out using the brazed and electroplated grinding wheel. The effects of grain distribution and grinding parameters on the grinding force, force ratio, surface profile wave, and surface roughness were studied. The results have shown that in similar operating conditions the brazed grinding wheel produced smaller grinding force, force ratio, smoother ground surface, and lower surface roughness compared to the electroplated grinding wheel. Additionally, for both grinding wheels, the UAG reduced grinding force, force ratio, surface roughness, and profile wave height. However, it also caused a more extensive ultrasonic vibration effect on grinding compared to the electroplated grinding wheel; its reduction percentage in grinding force was larger, while surface roughness and average height difference for UAG were higher compared to CG.
超声辅助磨削（UAG）是一种很有前途的加工硬脆材料的制造技术，主要是因为其出色的加工性能。在 UAG 中，运动学特性引起的磨粒轨迹相互作用和重叠的改善被认为是降低磨削力和提高加工质量的主要原因。然而，在现有的研究中，通常使用磨料颗粒分布无序和颗粒凸起高度不规则的砂轮。因此，很难同时控制磨粒轨迹的相互作用和重叠。为了解决这个问题，本研究提出了一种具有定义磨粒分布的钎焊金刚石砂轮。采用有限元分析设计砂轮基体，通过 UAG 的运动学分析得到磨粒分布。最后，采用钎焊技术制备砂轮，并制备具有相同基体和磨料粒度的电镀砂轮来验证其磨削性能。对两种砂轮的形貌分析表明，与电镀砂轮相比，钎焊砂轮的磨粒凸起高度更高且更均匀。下一步，使用钎焊和电镀砂轮进行 UAG 和 CG 实验。研究了磨粒分布和磨削参数对磨削力、力比、表面轮廓波和表面粗糙度的影响。结果表明，在相似的工作条件下，与电镀砂轮相比，钎焊砂轮产生的磨削力、力比更小，磨削表面更光滑，表面粗糙度更低。此外，对于两种砂轮，UAG 降低了磨削力、力比、表面粗糙度和轮廓波高度。然而，与电镀砂轮相比，它在磨削过程中产生的超声振动效应更为广泛；其磨削力的降低百分比更大，而 UAG 的表面粗糙度和平均高度差更高。
