Research On The Design And Fabrication Of Resin Grinding Wheels With 3-dimentional Controllable Diamond Abrasive Arrangement

During the grinding process,as the spatial position of abrasive particles in the grinding wheel has a major impact on the uniform abrasion of the grinding tool and the grinding quality of the workpiece,the design and fabrication of 3-dimensional(3D)controllable abrasive arrangement wheels is great importance.On the other hand,the orderly arrangement of abrasive particles,i.e.the location planning and control of abrasive particles on the surface of abrasive tools,can improve the chip-holding space,make the force of each abrasive particle and wear more uniformly,thereby improving the grinding performance of abrasive tools.At present,the research on two-dimensional abrasives(single-layer abrasives)confirms the important influence of abrasives arrangement on processing performance.Comparatively speaking,the 3D arrangement of abrasives has an important impact on the processing performance of grinding wheel and the stability of workpiece quality,but the research on 3D arrangement of abrasives is still rare.In this paper,based on the face grinding,the movement trajectory of single abrasive particle is conducted,the simulation of grinding process with 3D controllable abrasive arrangement grinding wheel is presented by using MATAB software.The influences of the abrasive distribution and the grinding parameters on the uniformity of the grinding trajectories were theoretically studied.The variation coefficient of standard deviation(VCSD)value was used to evaluate the uniformity of the grinding trajectories.As can be seen from the simulation calculation:(1)On the contact surface between grinding wheel and workpiece(X-Y direction),as the density of abrasive particles on the surface of abrasive tools increases and more concentrated in the outer ring,a better grinding trajectories will be obtained.(2)On the Z direction,during the grinding process,the smaller the change of the number of abrasive particles contacting the workpiece surface,the more stable the grinding process is.(3)There is no coupling effect between machining parameters and abrasive arrangement on the uniformity of trajectory.When the feed speeds increase,the uniformity of trajectory distribution on workpiece surface will be reduced.With the change of spindle speeds,the uniformity of trajectory distribution on workpiece surface fluctuates.Based on the additive manufacturing technology and single-layer controllable abrasive placement technology,a stereolithography apparatus equipment was developed for the fabrication of epoxy based grinding wheel with 3D controllable abrasive arrangement.The piece of equipment consisted of five parts: a resin-applying instrument,a grain-arrangement instrument,a resin-scraping and recovery instrument,a resin-curing instrument and a lifting instrument.The design of 3D controllable abrasive arrangement is digitally stratified,and the digital information of abrasive layer and resin layer is obtained respectively.The preparation of diamond 3D controllable abrasive arrangement grinding wheel was realized by combining resin stratification,light curing and abrasive template placement.The spatial position of abrasive particles in grinding wheels is detected,it is found that the leakage rate of abrasive particles is less than 0.5%,and the error between the spatial position and the design model is less than 10%.Experiments show that the equipment developed based on the principle of additive manufacturing can effectively realize the production of 3D controllable arrangement grinding wheels.Some UV-cured resin grinding wheels with different spatial arrangement of abrasive particles were prepared for the verification grinding experiments.The non-uniformity coefficient(NUC)of the ground surface roughness was used to evaluate the machining quality of the workpiece surface.It can be obtained from the experiment results that the abrasive distribution and grinding parameters had a significant influence on the quality uniformity of workpiece surface.Comparing with the grinding wheel with radial abrasive arrangement,the grinding wheel with 3D controllable abrasive arrangement had a longer effective grinding time and greater total material removal amount.The overlap ratio between abrasive layers has a great influence on the workpiece surface quality.Both the simulation results and experimental results indicated that the uniformity of the grinding trajectories could be optimized with the controllable abrasive arrangement.The failure mode of abrasive grains was observed.By improving the the properties of resin binder,the influence of holding force on the grinding properties of 3D controllable arrangement grinding wheels was studied.As can be concluded from the grinding experiments,the holding force of resin to abrasive particles has important influence on the change of abrasive particles in Z direction.Grinding experiment demonstrated the performance of UV resinoid grinding wheels was significantly improved with the addition particles.The grinding results show better agreement with the simulation results,and the error is reduced.Therefore,the grinding process and the grinding results can be predicted by improving the performance of UV resin and reducing the abrasive peeling.In this paper,the design and simulation calculation of grinding wheels with 3D controllable abrasive arrangement are carried out,and the manufacture of grinding wheels with 3D controllable abrasive arrangement are realized.The space position of abrasives is in good agreement with the designed arrangement.The simulation results are verified by grinding experiments.This method can be used to provide reliable theoretical basis for predicting the stability and quality of grinding tools with different spatial positions.