Simulation And Experimental Study On Ultrasonic-assisted Belt Grinding Of Aluminum Alloy

In recent years, abrasive belt grinding which is a combination of grinding and polishing as a new technology with the characteristics of elastic grinding, high quality, high efficiency, low cost, etc.. However, it can cause adhesion and clogging during the processing when belt grinding is applied to machine high plastic metal material such as aluminum alloy, which will undermine the surface quality of the product. And the surface quality will directly affect the performance and service life of the product. The most common method of improving grinding effect was introduced ultrasonic vibration for grinding process in existed researches. And these researches almost explored the influence of ultrasonic vibration on grinding effect from experiments, but the studies of theoretical analysis and numerical simulation on micro exploring was seldom. It is important significance that combine theoretical analysis, numerical simulation and experiment research to explore laws and reasonable parameters, cause it will affect the grinding effect that grinding grains arrangement and shaper were uniform.This paper developed the simulation and experimental study of ultrasonic vibration abrasive belt grinding aluminum alloy materials based on the abrasive belt grinding process which used Zirconia corundum abrasive belt and 6063 aluminum alloy as the research object. The finished jobs mainly includes the following parts:(1) Measured abrasive belt surface morphologies and established the cutting edge distribution based on the 3D scanning technique. Using laser scanning confocal microscope to measure 120# abrasive belt surface morphology, and rebuilt abrasive belt morphologies after removing noise components by using the mean filter. The abrasive edge distribution model was established and normal fitted by using grains density and the mean spaces.(2) Predicted abrasive belt surface topography and roughness after grinding. According to the kinematics analysis of grinding process, the equations of grains motion about ordinary grinding and ultrasonic vibration grinding process was established. Predicted the simulation grinding surface morphology and surface roughness based on MATLAB generated surface algorithm, mean while studied the influence of ultrasonic vibration on surface morphology.(3) predicted grinding force based on single grain grinding process. According to the actual grains shape, there are four kinds of typical shape with statistic methods. The single grain grinding process have simulated with the finite element ABAQUS. At the same time, combining the grits distribution and the single grain force to predict the grinding force and comparing the difference of grains shape.(4) Verified the accuracy of prediction about roughness and grinding force by experiments. The reliability of numerical simulation model is verified by building the experimental platform.