| With the continuous development of modern manufacturing,the concept of product manufacturing has changed from the original forming process to the pursuit of high precision,high performance and high quality.Grinding has become the main processing method for parts manufacturing due to its high processing quality and processing efficiency,accounting for 30%-40% of the total machining.However,due to the complexity of the shape of the grinding wheel,it is difficult to study the grinding mechanism and predict the grinding results.With the continuous development of computer technology,simulation calculation has become an effective means to study the grinding mechanism and predict the grinding process.By developing a grinding simulation modeling platform,abrasive grain and grinding wheel models can be provided for grinding simulation,and combined with the finite element method,efficient research on the grinding process and grinding process can be achieved.1)The Dialnspect-OSM superabrasive automatic analysis system and the VHX-2000 FE ultra-deep depth microscope was used to observe the diamond abrasive grains of 60#~70# and the diamond grinding wheel with the size of 80/100,combined with other scholars' research.As a result,the shape and size of diamond and CBN grinding,the surface morphology of the grinding wheel,the distribution of abrasive grains on the surface of the grinding wheel and the height of the abrasive blade were studied.2)The abrasive grain modeling based on the virtual ball tangent plane space segmentation regular hexahedral matrix algorithm,and the grinding wheel modeling algorithm controlled by random function after the ordered arrangement of abrasive grains,developed the grinding simulation rapid modeling platform based on Abaqus in Python language;3)Quickly created a single abrasive particle model using the platform and grinding wheel model is used for grinding finite element simulation.Combined with GCr15 bearing steel surface grinding test,the influence of grinding process parameters on grinding force during grinding process and the surface roughness of workpiece and residual stress on workpiece were studied.The results show that the shape of CBN abrasive grains and diamond abrasive grains are mostly eight to tetradecahedrons,and the size is within a range and follows a normal distribution.The surface of the grinding wheel is randomly distributed by a plurality of abrasive grains.The bonding agent and the grinding wheel base are combined,and the abrasive blade edge height obeys the normal distribution;the grinding simulation rapid modeling GUI platform can parameterize the random polyhedral abrasive grain and the simulated grinding wheel model;The simulation results are consistent with the trend of the test results.The grinding force increases with the increase of the workpiece feed speed or the grinding depth.The maximum error of the normal grinding force is 9.65%,which is much smaller than the tangential grinding.Residual stress on the surface of the workpiece measured after plane test,under the condition of other process parameters,the residual compressive stress decreases with the increase of the feed rate of the workpiece.The residual compressive stress gradually increases with the increase of the grinding depth.when the grinding depth reaches 20 ?m,the residual compressive stress is transformed into tensile stress;the distribution of residual stress in the surface of the workpiece is consistent with the overall trend of the experimental results,but due to the incompleteness of the simulation process,the specific numerical value is a certain error to the test;Overall,the simulation results are consistent with the experimental results,which proves the effectiveness of the grinding simulation modeling platform,but the simulation accuracy needs to be further improved.The research results provide a new idea using finite element method to study the grinding mechanism and control the processing quality. |
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