金刚石与磨料磨具工程2025，Vol.45Issue(1)：67-74,8.DOI:10.13394/j.cnki.jgszz.2024.0003
基于当量磨削层厚度的整体刀具容屑槽磨削功率模型
Grinding power model for flute grinding of solid tools based on equivalent chip thickness
摘要
Abstract
Objectives:During the flute grinding process of solid tools,the majority of grinding power is converted in-to grinding heat.Excessive grinding power can cause a rapid temperature rise on the surface of the contact area between the grinding wheel and the tool,which can easily lead to grinding burns and eventually tool failure.A grinding power model for flute grinding of solid tools is proposed based on equivalent chip thickness,aiming to achieve precise predic-tion and control of grinding power for flute grinding.Methods:A kinematic model for flute grinding is established us-ing homogeneous coordinate transformation.On this basis,according to the theory of conjugate surfaces,the instantan-eous contact line between the grinding wheel surface and the flute surface during the grinding process is obtained,and the grinding wheel is discretized into a set of equally thick grinding wheel slices.The grinding contact arc length is ob-tained by calculating the intersection points between the grinding wheel slices and the tool cylindrical surface.Flute grinding is regarded as external cylindrical grinding with a special contact zone shape.By introducing the contact-area-shape coefficient to define the equivalent grinding depth and the equivalent feed rate of each grinding wheel slice,the formula for calculating the equivalent grinding layer thickness of flute grinding is derived.When the linear speed of the grinding wheel,the axial feed speed of the workpiece,and the grinding contact arc length of each grinding wheel slice are known,the equivalent chip thickness of each grinding wheel slice can be calculated as long as the shape coefficient of the contact area is given.The cross-section profiles of the chute are discretized into small triangles,and the area of the cross-section profile of the chute is obtained by calculating the area of each triangle.The material removal rate of the chute during grinding is determined by combining the axial feed velocity of the workpiece.According to the principle of conservation of material removal rate,the formula for the shape coefficient of the contact area is derived.Based on the mathematical relationship between the local grinding power of each grinding wheel slice and the thickness of the equi-valent grinding layer,the empirical model for flute grinding power is established.The experimental verification of the model is carried out on an ANCA MX7 CNC tool grinding machine.The flute with a spiral angle of 30° is ground on a cemented carbide rod with a metal-bonded diamond wheel.The spindle power data of the machine tool PLC is recorded using the data recording function of iGrind grinding software.The spindle power includes grinding power and spindle idle power,so grinding power is obtained by subtracting idle power from spindle power.Twenty sets of grinding experi-ments are carried out under different grinding parameters,and an overdetermined equation set is established by substi-tuting the grinding power data of four sets of experiments into the power model.By solving this equation system,the two empirical constants in the model are obtained.Then,the grinding power model is used to predict the grinding powers of twenty sets of grinding experiments,and the predicted grinding powers are compared with the actual grinding powers.Results:The comparison results show that the predicted grinding powers are close to the actual grinding powers,and the maximum relative error of the predicted grinding power is less than 15%.The equivalent chip thickness of each wheel slice and the grinding power per unit width vary gradually along the width of the grinding wheel,and the maximum equivalent chip thickness and the maximum grinding power per unit width exist at the edge of the grinding wheel.Conclusions:The proposed grinding power model based on equivalent chip thickness can precisely predict the grinding power during the flute grinding process of solid tools,and obtain the distribution of grinding power in the width direction of the grinding wheel.The grinding power can be precisely controlled by adjusting grinding parameters with this model,and the maximum equivalent chip thickness and the maximum grinding power per unit width exist at the edge of the grinding wheel during the grinding process of the chute,which will lead to non-uniform wear in the dir-ection of the width of the grinding wheel.关键词
整体刀具/容屑槽/磨削功率/当量磨削层厚度/螺旋槽Key words
solid tool/flute/grinding power/equivalent chip thickness/helical groove分类
金属材料引用本文复制引用
任磊,潘江涛,向道辉,马俊金,崔晓斌..基于当量磨削层厚度的整体刀具容屑槽磨削功率模型[J].金刚石与磨料磨具工程,2025,45(1):67-74,8.基金项目
国家自然科学基金青年项目(52005165) （52005165）
河南省科技攻关项目(242102221016). （242102221016）
