Modeling Of Grinding Wheel And Study On The Grinding Simulation Of Alumina Ceramic Based On Discrete Element Method

Engineering ceramics have been widely used in machinery,national defense,aerospace,electronics,automobiles and other fields because of their excellent properties.Due to the inherent hardness and brittleness of engineering ceramics,grinding with diamond grinding wheel is still one of the main means to achieve precision and ultra-precision machining of ceramic materials.With the continuous requirements of precision,reliability and service life of the mechanical products,many difficulties have occurred to grinding process.Grinding process is essentially a mass of abrasive grains discretely distributed on the surface of the grinding wheel acting on the workpiece.As to the simulation of grinding process,the establishments of the models of single abrasive grain and integral grinding wheel are important.Therefore,it is necessary to study the influence of abrasive grains' shape,size and spatial distribution on grinding process starting from the microscopic characteristics of single abrasive grain.In this paper,vitrified diamond wheel was the study subject,the influence of the surface morphology parameters of the grinding wheel on grinding process of alumina ceramics was studied by experiments and numerical simulations.The main research contents are as follows:(1)Vitrified diamond wheel of 120#and diamond powder of 80#,100#and 120#were selected.The distribution,shape and size of the abrasive grains were detected by optical microscope and ultra-field depth microscope.Then the results were analyzed to get the basis for modeling.(2)The models of alumina ceramic,matrix,single abrasive grain and bond strength for abrasive grains were established in the software PFC3D.Then the mechanical properties of the models were calibrated through numerical simulations,so that models were consistent with the actual material.(3)The single abrasive grain cutting simulation models of alumina ceramic were obtained by combining with the alumina ceramic model and single abrasive grain models.The influence of the abrasive grains' shape on cutting process under different parameters was studied through simulations.And cutting experiments of single abrasive grain were done,then a comparative analysis was carried out.(4)By changing the arrangement of abrasive grains on the matrix surface,and combining with the alumina ceramic model,different simulation models of grinding process were obtained.The influence of different abrasive grain arrangement on grinding process was studied through simulations.And grinding experiments were done,then a comparative analysis was carried out.