Study On Material Removal Mechanism Of Ultra-high-speed Grinding

Ultra-high-speed grinding is the development trend and direction of grinding technology. Because of the incomparable advantages of better surface quality and higher production efficiency over other machining methods, ultra-high-speed grinding gets the attention of world. The development of ultra-high-speed grinding in our country is very late, in order to be able to catch up with the level of technology in Germany, Japan, the United States, etc and better promote the development of the domestic manufacturing sector, there is an urgent need to invest a lot of researchers and funds for research of ultra-high-speed grinding theory, technology and related equipment. Material removal is the fundamental purpose of grinding.Therefore, this paper relies on Shanxi Natural Science Foundation of China (2013011024) and selects ultra-high-speed grinding material removal mechanism as the research direction, in order to contribute meager force to the development of ultra-high-speed grinding career.Firstly, by analyzing the characteristics of grinding, the cone abrasive model, whose apex is spherical, has been built. Based on this model,the theoretical formula of tangential grinding force and normal grinding force of single abrasive grit and grinding wheel in ultra-high speed grinding have been deduced. Three stages of the grinding machining, effect of normal grinding force and tangential grinding force and grinding force ratio were analyzed.The trajectory equation of abrasive grit on grinding wheel has been deduced, and the trajectory curve has been drawn by MATLAB software. By analyzing the trajectory curve, the geometry model of single abrasive grit grinding was built.Secondly, workbench software is used to simulate single abrasive grit material removal process. The main conclusions are as follows:Firstly, single abrasive grit grinding process is divided into three stages obviously, which are swipe stage, plowing stage and material removal stage; in material removal stage, the impact of the abrasive grit become a more important source of the internal stress of material contact area. Due to the dual function of impact and friction, under pressure of the abrasive grit and the follow-up material into the contact area, material in the contact area becomes chips and overflows. Secondly, when the grinding depth reaches the critical grinding depth, the chip will form. At the same condition, the higher the grinding speed, the smaller the critical grinding depth; when other parameters are the same, the bigger the abrasive grit cutting edge radius, the smaller the critical grinding depth; when other parameters are the same, if workpiece material is different, the critical grinding depth is different. Then, if the other parameters are the same, the larger the cutting edge radius, the bigger the plastic deformation zone. Finally, in swipe stage and plowing stage, with the grinding depth becoming large, the maximum equivalent stress of workpiece material becomes large; in material removal stage, the maximum equivalent stress of the workpiece material is stable.In this paper, single abrasive grit grinding experiment method of ultra-high-speed grinding was designed, and its parameter selection and analysis method of its results was analyzed.