考虑机床-磨削交互的工件表面形貌仿真

Simulation of surface topography considering process-machine interaction in grinding

磨削加工方法是保证加工表面质量的重要手段,机床结构与磨削过程之间存在的交互作用会对工件表面质量产生不利影响。以砂轮端面磨削加工过程为研究对象,在研究磨削工件表面形貌仿真方法的基础上,深入分析了机床结构与磨削过程之间交互作用对工件表面形貌的影响。首先基于砂轮表层磨粒的随机分布特性建立了虚拟砂轮形貌,然后通过对磨削过程中砂轮磨粒与工件几何干涉作用的分析,建立了磨粒运动轨迹方程和工件表面形貌方程。考虑砂轮变形对磨削过程的反向作用,建立了主轴-砂轮结构与磨削过程间的交互模型,采用耦合仿真的方法对机床-磨削交互过程进行了仿真,并考虑磨削过程中的交互作用提出了一种新的磨削工件表面形貌仿真模型,实验结果验证了所给算法的正确性和有效性,该方法为进一步优化磨削工艺参数提供了依据。

Grinding is an important means to guarantee the quality of the machined surface,however,the interaction between machine and grinding process reduces surface quality. Focusing on face grinding,the influence of process-machine interaction on ground surface was analyzed based on the investigation of surface topography simulation. A visual wheel topology was simulated based on the random nature of grains located on the wheel surface. The grain trajectory equation and workpiece topography equation were established based on the analyses of interference between grains and workpiece. The interaction between grinding process and spindle-wheel was modeled considering the inverse influence of wheel deformation on process and simulated by adopting a coupling simulation method. Taking the processmachine interaction into account,a novel simulation model for surface topography of the grinding process was proposed.Grinding test verifies the accuracy and effectiveness of the given algorithm. The method can be further used to optimize the grinding process parameters.