Research On Hob-Grinding Structured Surface By The Superabrasive Grinding Wheel With Abrasive Phyllotactic Pattern

Structured surfaces have many advantages that are not available on smooth surfaces and most widely used in mechanical engineering to effectively reduce fluid drag resistance on the surface of parts and improve their motion in fluids.Therefore,how to manufacturing structured surfaces has been brought into focus in mechanical processing.Based on the phyllotaxis theory of biology,the phyllotactic pattern applied to abrasive ordering pattern of the grinding wheel,and process structured surface with the hob-grinding wheel.In order to explore the mechanism of the structured surface grinding,the kinematics simulation was carried out on the grinding process of superabrasive hob-grinding wheel with phyllotactic pattern,The influences of rotational speed ratio,axial feed speed,grinding depth,installation angle and phyllotactic coefficient on the structural surface morphology were obtained.By selecting proper processing parameters,different grooves and dimples surfaces were obtained by simulation,the feasibility of applying a hob-grinding wheel to process a structured surface has been proved.A variety of pattern hob-grinding wheels were designed and produced by electroplating according to simulation parameters.A large number of comparative experiments were carried out to analyze mask pore size,abrasive grain sorting,electroplating solution component,electroplating process and conditions,detection of hob-grinding wheel and removal of unqualified nickel layer.A complete process of electroplating grinding wheels was developed,and a solid foundation for subsequent hob-grinding experiments was laid.The prediction on the principles of the way relevant parameters influence the structured surface morphology was verified,and the expected structured surface was obtained,all of which had proved the feasibility of applying the grinding method to process the structured surface.The simulation results show that the speed ratio between hob-grinding wheel and workpiece determines the number of grooves,and the distance between grooves decreases as the speed ratio increases;the smaller the axial feeding speed is,the lower the waviness of the grooves will be,and when the axial feeding speed exceeds the critical axial feeding speed,the groove surface will not be generated;as the depth of grinding deepens,the section size of grinding mark becomes larger and the length of grinding mark becomes longer.Therefore,a conclusion is drawn that highest speed ratio,lower feeding speed and deeper grinding should be the best option during the structured surfaces processing.