Research On Material Removal Of Softness Adhesive Regional Consolidation Abrasives For Localized Hardening Molds

In mold industry, laser hardening could not only significantly improve surface hardness, wearing resistance and corrosion resistance, but also optimize performance of mold and extend its service life. However, these advantages have also brought tremendous difficulties to the finishing process of laser hardening surface, such as irregular freeform surface, high hardness and local difference of hardness.Based on the distribution of hardness of localized hardening molds and combined with the theory of micromechanics, contact mechanics and fracture mechanics, analysising cluster abrasives-effect and mechanism of material removal in this paper. Using same software such as PFC3 D and Matlab to simulate the consolidation abrasives with different particle mesh and diverse binder percent in the different regionation of the wheel. And then obtaining the influence of material removal Under these simulations and same experiments. The main contents and results are as follows:1. Based on the contact type of Particulate matters, we get the macroscopic mechanical properties of the abrasive group by using the DEM soft PFC3 D to establish the model of the abrasives layer and analyzing the relationship of the internal coordination, the evolution of the contact forces and the sliding ratio and stress-strain with the different particle mesh and diverse binder percent under the monotonic loading, which can provide the feasibility of regionalization bonded in the wheel. And then through the experiments show the accuracy of the simulation model,2. Based on Hertz contact theory of establishing a model about material removal of a single grain under the flexible support conditions and the theory of fracture dynamics, we get the number of valid abrasives on the surface. Then on condition of the same cutting speed and force, the impact of different material removal of abrasive layer and its simulation analysis is important to establish a finishing plan about adhesive regionalization.3. According to the distribution of the contact stress and the grinding speed of the Pressure Grinding Wheel with Soft Abrasive Consolidation, we can obtain the predicted model about material removal of abrasive layer. And then depending on the distribution of hardness of localized hardening molds, we can set up a material removal model in the contact area according to the intensified ratio in the whole contact area. Through the experiments prove that we can greatly improve the surface quality after the finishing by changing the intensity in the contact area and non-contact area and local hardness differences to remove the material evenly.This research provides a certain reference to the use of pneumatic grinding wheel with soft abrasive in the process of finishing for Discrete Element. It also provides a certain engineering mentoring to the finishing process of mold laser intensifying free-formed surface, especially localized surfacing finishing.