The Experimental Study On Grinding Forces And Grinding Temperature Based On Ultrasonic Vibration Assisted Surface Grinding

Ultrasonic vibration assisted grinding(UVG)is a kind of compound machine technology that combines the characteristics of ultrasonic vibrational machining and material removal mechanism of common grinding(CG),which has been widely applied in the grinding process of hard to difficult-to-cut material such as hard and brittle materials,superalloy and cemented carbide,which has advantages in reducing the grinding forces,decreasing the wear of wheel,and improving the workpiece surface quality.Recently,many studies have been conducted on the UVAG,however,the grinding mechanism of UVAG is complicated,and the ultrasonic vibration change the relative motion between the grinding wheel and workpiece,which make it difficult to analysis the grinding mechanism.This study presents the change law of grinding forces and grinding temperature to study the UVAG,which provides the theory basis for further study on UVAG.The main research work of this study is:(1)The simulation research on ultrasonic vibration workbench has been conducted based on modal analysis and harmonic response analysis using the ANSYS Workbench,by comparing the theoretical calculation values of amplitude,the rationality of workbench was verified.(2)Considering the grain tips' randomness,on the basis of statistics phenomenon of chip thickness,by analyzing the contact length within the contact zone in grinding process,the model of grinding force was proved.By comparing with the experimental grinding forces,the numerical model of grinding force is analyzed.(3)The new model of heat source was proved on the basis of chip thickness analysis.To study the influence of heat flux models and grinding fluid on temperature field,the FEM simulation has been conducted for some typical conditions using the provided heat source model.The reliability of provided model was verified by comparing with the experimental grinding temperatures.(4)The wheel wear has direct effects on cutting performance of grains,which make the effects time of rubbing and plowing different in grinding process.Considering the influences of rubbing and plowing effects of abrasive and work piece on the heat flux,the Rectangle-arc distribution was established.Finally,the numerical prediction was developed based on the relationship analysis between cutting performance and grinding temperature field.(5)The discussion is focused on the influence factors of surface roughness and residual stresses on the basis of formation mechanism of machined surface,and then the influence of grinding parameters on surface roughness is analyzed using the experimental results,and the effect of UVAG on surface integrity is also discussed.(6)Finally,this study sums the innovative achievements and the deficiencies when considering some problems and the research prospect for UVAG is provided.