Simulation And Experimental Research Of Diamond Grinding Wheel 3D Shape Modeling And Cutting Engineering Ceramics

Engineering ceramics with high hardness, high strength, high temperature resistance, wear resistance, chemical corrosion resistance, good performance of self lubricity, has been widely used in the field of electronic technology, energy technology, chemical, aerospace and other science, but the fracture toughness is so poor that it become the typical difficult to machine materials, the precision machining of the engineering ceramics and other hard materials processing at present is mainly by precision grinding with super-hard fine abrasive to achieve. In order to deepen and promote the application of engineering ceramics, more researching should be taken toward the precision grinding of engineering ceramics. we can better understand the complex grinding process through the study of single abrasive grain cutting processing, which can simplify the analysis of grinding and surface damage theory. Through set the simulation model of the grinding wheel surface topography, the research on the grinding behavior has became more intuitive, and thus contribute to the accurate evaluation and prediction the grinding performance of the grinding wheel. In this paper, taking the precision grinding of silicon nitride ceramics as the research object, through the grinding wheel surface topography measurement result analysis, established a single abrasive and grinding wheel surface topography model using numerical simulation technology. at the same time,carry out the single grit cutting simulation, the whole simulation of grinding wheel, finally through single grit cutting experiment and the grinding experiments to validate the analysis about the morphology modeling and simulation, the research contents include:(1) Make surface topography measurement of grinding wheel, and through the grinding particle surface area density, grain number, average height of protrusion of the analysis, using the method of spherical coordinates plane cutting solid to established the virtual single particle model which more close to the actual,at the same time, analyzed the relationship between the grinding blade dihedral angle and the integral optical density value; using normal random number method to establish the surface topography model of grinding wheel which has a random distribution characteristic of grit size, position and angle; verified the effectiveness of virtual polyhedron abrasive and grinding wheel model combined with the wheel surface area density, grain average number, protrusion height and other parameters.(2)using the geometric model that cutting by spherical coordinate to simulate the diamond grits. meanwhile, using JH-2 material constitutive model and the SOLID164 entity unit to establish finite element simulation model of a single grain, and meshed it with a variety of methods, through the LS-DYNA conducted the single grain cutting process simulation, and analyzed the stress,cutting scraps,cutting force and other microscopic phenomena of the workpiece. Finally,conducted the single grain cutting test, verify the validity of the simulation.(3)using the DEFORM-3D to build the finite element simulation model of diamond grinding wheel and silicon carbide ceramic workpiece,and conducted the simulation to analysis the formation process of sliding friction, plows, cutting. Through the simulation analyzed the material removal process and cutting force fluctuations under microstructure, studied the effect of rotating speed and grinding depth on grinding force and the workpiece stress. Finally,compared and analyzed the results with grinding experiment, verified the rationality of the simulation.