基于不同单颗磨粒模型的微细磨削力研究

Study on Micro-grinding Force Based on Different Single Abrasive Particle Models

微细磨削技术能够实现硬脆材料复杂结构微小零件的高精高效低成本加工.通过深入分析微细磨削机理,考虑刃角圆弧半径的影响,建立了圆锥、球形、三棱锥、四棱锥等4种单颗磨粒切削力模型;采用VHX-1000超景深光学显微镜对Φ0.5mm、#600微磨棒表面磨粒形状进行观测分析并统计,建立了基于单一磨粒模型和基于综合磨粒模型的微细磨削力模型;在ZCuZn38上进行微细磨削试验,对比研究了微细磨削力理论计算结果与试验结果,并基于理论模型讨论了微细磨削力随工艺参数的变化规律.结果表明,单一磨粒模型微细磨削力与综合磨粒模型微细磨削力均能预测不同工艺条件下的微细磨削力,但综合模型微细磨削力的误差最小;不同磨粒模型计算得出的法向磨削力较为一致,但切向磨削力差异较大.

Micro-grinding technology is able to achieve high-precision,high-efficiency and low-cost machining of micro-parts on hard and brittle materials.Based on the deeply understanding of micro-grinding mechanism,the cutting models of single abrasive particles including cone,sphere,triangular pyramid and rectangular pyramid were established,which took the radius of edge arc into account.The abrasive particle shape and distribution of the micro-grinding tool with Φ0.5 mm,#600 were observed and counted by ultra depth optical microscope VHX-1000.Then the micro-grinding force models based on single abrasive particle models and comprehensive abrasive particle model were established.The micro-grinding experiment was performed on the ZCuZn38 and the measured micro-grinding force was compared with that obtained from micro-grinding models.The change of micro-grinding force with process parameters was discussed according to the proposed micro-grinding force models.The results show that the micro-grinding force models based on single type of abrasive particles and different types of abrasive particles can predict the micro grinding force under various process parameters.However,the micro-grinding force model based on different types of abrasive particles has minimal error.The normal grinding forces calculated from different single abrasive particle models are close,but the calculated tangential grinding forces are obviously different.