Study On The Formation Mechanism Of Compound Macro And Microscopic Topography To Grind Surfaces Based On Large Spiral Angle Groove Grinding Wheels

High-efficiency grinding technology has become one of the important development directions of modern manufacturing technology with its characteristics of determinism,high efficiency and high precision,and is effectively used in precision machining and ultra-precision machining,which is a machining means that can balance machining efficiency and machining quality.How to effectively reduce the grinding temperature is the core problem in the research of high-efficiency grinding technology,especially when grinding difficult-to-machine materials such as high-strength steel,titanium alloy and polymer materials.From the perspective of improving the heat transfer performance of the grinding arc and controlling grinding burns,the structured grinding wheel with large spiral angle grooves,whose groove direction is consistent with the grinding direction and cutting fluid flow direction,makes it easier for the grinding fluid to enter the grinding arc and form a smooth heat transfer channel inside the grinding arc,thus significantly improving the heat transfer capacity of the grinding arc,and is a type of structured grinding wheel with broad application prospects.However,the factors that limit the large-scale engineering application of large spiral angle groove grinding wheels are also very obvious: during the grinding process,the phenomenon of complex replication effect is generated,which leads to the degradation of grinding surface quality.The formation process of workpiece surface microformation is complex,and a relatively complete theoretical system has not yet been formed for the research related to the structured wheel grinding surface formation mechanism considering both macroscopic surface regularity and randomness of microscopic abrasive grain distribution.Based on the above analysis,this paper constructs a grinding processing model based on the structured grinding wheel with large spiral angle grooves,proposes the suppression strategy of the complex replication effect at the macro level,and reveals the formation mechanism of the workpiece surface profile features at the micro level.In this regard,the following work is carried out in this paper:1.Based on the kinematic relationship between the grinding wheel and the workpiece during the grinding process,the macroscopic surface morphology regular large spiral angle groove structured grinding wheel model was established by numerical analysis and theoretical derivation,the complex replication effect coefficient was defined,the influence law of the grinding wheel surface structure parameters and grinding process parameters on the complex replication effect coefficient,groove area ratio and grinding arc length was analyzed,the formation mechanism of the macroscopic surface morphology of the workpiece was studied,and the complex replication effect suppression strategy was constructed.The mechanism of macroscopic surface profile formation was investigated,and a strategy for suppressing the crosstalk effect was developed.2.In view of the random distribution of abrasive grains on the circumferential surface in the grinding wheel manufacturing process,a theoretical analysis model of randomly deflected single grain cutting was constructed,and the specific mathematical relationships between the length of the cutting trajectory of a single grain,the shape of the chip,the thickness of the undeformed chip,the volume of material removal and the material removal rate and the process parameters were obtained.The effects of different grinding parameters and deflection parameters on the length of the cutting trajectory,the shape of the chip,the thickness of the undeformed chip,the volume of material removal and the material removal rate were analyzed,and the influence mechanism of the randomness of the deflection angle was studied.3.Based on the random distribution characteristics of microscopic abrasive grains on the circumferential surface of the grinding wheel,the microscopic interaction and geometric motion between the abrasive grains and the workpiece were analyzed and studied in depth,the macroscopic morphology model of the large spiral angle groove grinding wheel was extended to a microscopic surface abrasive grain random distribution mathematical model,the number of abrasive grains involved in cutting on the surface of the grinding wheel was calculated,and the macroscopic grinding surface profile of the workpiece was compared.The surface contour of the workpiece is compared;the mechanism of the formation of the microscopic morphology of the workpiece surface is studied,and the influence law of the grinding wheel surface structure parameters and grinding process parameters on the height of the protruding ridge and the surface roughness of the workpiece is analyzed to verify the feasibility and effectiveness of the complex replication effect.The mechanism of compound influence of the regularity of macroscopic surface morphology and the randomness of microscopic abrasive grain distribution on the macroscopic morphological characteristics of the workpiece grinding surface is revealed for the structured grinding wheel with large spiral angle grooves.