基于随机碰撞的GCr15钢强化研磨表面粗糙度数值模拟

Numerical Simulation of Surface Roughness of GCr15 Steel Strengthened Grinding Based on Random Impact

目的探索强化研磨工艺参数对表面粗糙度的影响规律。方法采用小球均布大球模型来模拟研磨粉附着在钢珠表面对工件的强化作用,基于Abaqus/Python建立强化研磨随机碰撞有限元模型,设置不同喷射速度、喷射角度、钢珠直径、喷射时间等工艺参数进行仿真模拟。运用Matlab提取靶材表面形貌,并基于此形貌,沿4种不同路径计算表面粗糙度,分析不同参数下表面粗糙度的变化规律。结果随喷射时间的增加,强化研磨表面粗糙度先增加,后趋于稳定。喷射角度θ为90°,钢珠直径D为0.8mm,喷射速度v分别为30、50、70 m/s条件下,随着喷射时间的增加,表面粗糙度增加至稳定后,分别在1~1.2、1.7~1.9、2~2.5μm波动;喷射速度v为50 m/s,钢珠直径D为0.8mm,喷射角度θ分别为30°、60°、90°条件下,随着喷射时间的增加,表面粗糙度增加至稳定后,分别在1.1~1.3、1.5~1.7、1.7~1.9μm波动;喷射速度v为50 m/s,喷射角度θ为90°,钢珠直径D分别为0.4、0.8、1.2 mm条件下,随着喷射时间的增加,表面粗糙度增加至稳定后,分别在0.7~0.8、1.7~1.9、2.4~2.6μm波动。经过试验验证,发现试验结果与仿真结果平均误差为8.15%。结论强化研磨随机碰撞有限元模型能可靠预测强化研磨工艺下工件的表面粗糙度,可为后续研究提供理论基础。

The paper aims to explore the law of the influence of strengthening grinding process parameters on the surface roughness.The effect of abrasive on the workpiece was simulated by the model of small balls uniformly distributed on the surface of large balls,Based on Abaqus/Python,a finite element model of random impact of intensified grinding was established,the process parameters such as different jet speed,jet angle,steel ball diameter and jet time were set for simulation.The surface morphology of the target was extracted by MATLAB.The surface roughness was calculated according to the four different paths of the surface topography,and the variation rule of the roughness under different parameters was analyzed.The results were as follows:With the increase of jet time,the surface roughness of the strengthened grinding surface increases first and then tends to be stable.When the jet angle is 90°,the diameter of the steel ball is 0.8 mm,and the jet speed is 30,50,70 m/s,the surface roughness increases with the jet time and stabilizes to 1~1.2,1.7~1.9,2~2.5μm.When the jet speed is 50m/s,the diameter of the steel ball is 0.8 mm,and the jet angle is 30°,60°,90°,the surface roughness increases with the jet time and stabilizes to 1.1~1.3,1.5~1.7,1.7~1.9μm.When the jet speed is 50 m/s,the jet angle is 90°,the diameter of the steel ball is 0.4,0.8,1.2 mm,the surface roughness increases with the jet time and stabilizes to 0.7~0.8,1.7~1.9,2.4~2.6μm.It was found that the error between test results and simulation results is 8.15%.Therefore,the finite element model of random impact of strengthening grinding can reliably predict the surface roughness of strengthening grinding process and provide theoretical basis for subsequent research.