金刚石与磨料磨具工程2025，Vol.45Issue(1)：1-11,11.DOI:10.13394/j.cnki.jgszz.2024.0013
基于加工形貌数据聚类的单点金刚石磨削稳定性及工艺调控
Stability and process control of single-diamond grinding based on clustering of processing morphology data
摘要
Abstract
Objectives:In the precision grinding process of hard mold steel workpieces,the subtle changes in machin-ing depth can significantly cause dynamic changes in the magnitude and the direction of grinding forces,which directly lead to unstable machining conditions and affect machining accuracy and surface quality.To this end,the data cluster-ing analysis is used to analyze the machining morphology data of the workpiece,and the stable single-point grinding of the workpiece is achieved through process control.Methods:Using large particle diamond single-point grinding for hard mold steel,the dynamic characteristics and the stability of the grinding process are analyzed based on the morpho-logy characteristics of the diamond processing surface.The influences of the process parameters on diamond processing efficiency and surface quality are explored to achieve high-efficiency and high-quality diamond grinding.Firstly,the dy-namic modeling of the single point diamond grinding system is carried out,and the grinding vibration signal is meas-ured by an accelerometer.The working mode analysis is performed to solve the natural frequency and the damping ratio of the machining system.Then,using a laser confocal microscope to obtain surface waviness and surface roughness data under different processing conditions,the feed depth and the wheel speed are correlated with the data clustering under stable conditions,and matched with the blade diagram area under stable grinding conditions to fit the stiffness and the grinding force coefficients of the processing system.A real-time control area for feed depth and the wheel speed during the stable grinding process is constructed.Finally,the machining efficiency and the quality of the mold steel are veri-fied and analyzed through grinding experiments.Results:The modal analysis of the grinding process and the clustering matching of the machined surface morphology features can map the machining process parameters in the stable domain of the grinding process.The working mode analysis method is applied to the stability analysis of single-point diamond grinding die steel,and the natural frequency and the damping ratio of the process system can be obtained under the working state.The natural frequency of the single-point diamond grinding die steel process system is fn=363 Hz,and the damping ratio ξ=0.027.The clustering analysis method is applied to the machining state classification,and the ma-chining surface can be divided into stable machining and unstable machining according to the internal relationship between the surface waviness Wa and surface roughness Ra data.The surface morphologies of the two types of machin-ing are obviously different.The surface of the stable processing state is smooth and flat,while the surface of the un-stable processing state has a large area of plastic deformation and a large number of burrs.The surface machining qual-ity of single-point diamond grinding die steel differs greatly under stable and unstable machining conditions.The aver-age surface waviness Wa of single-point diamond grinding mold steel in the stable processing state is 0.635 μm,and the average surface roughness Ra is 0.143 μm.The average surface waviness Wa in the unstable state is 1.203 μm,and the average surface roughness Ra is 0.267 μm,which is about twice that of the stable state.The experimental points after clustering analysis are matched to the relevant areas on the grinding stability lobe diagram,and the experimental verific-ation is carried out to obtain the system stiffness coefficient k=7×106 N/m and the grinding force coefficient km'=3×1015 N/m3 of the single-point diamond grinding die steel process system.Conclusions:In the stable processing state,the single-point diamond grinding die steel can achieve a greater material removal rate while ensuring the surface quality as much as possible,thus improving the processing efficiency.In the case of the same amount of material removal,the sur-face roughness Ra of the stable region processing state is reduced by 74%on average compared with that of the unstable region processing state,which realizes the high-efficiency and the high-surface-quality machining of high-hardness met-al materials.关键词
单点金刚石/磨削稳定性/聚类分析/表面质量/表面粗糙度Key words
single-diamond/grinding stability/cluster analysis/surface quality/surface roughness分类
化学化工引用本文复制引用
徐鑫宇,贺先送,陈钊杰,张竞颖,杨林丰,谢晋..基于加工形貌数据聚类的单点金刚石磨削稳定性及工艺调控[J].金刚石与磨料磨具工程,2025,45(1):1-11,11.基金项目
国家自然科学基金(52375493) （52375493）
广东省基础与应用基础研究基金(2022A1515220053). （2022A1515220053）
