Material Removal Mechanism And Surface Generation In Surface-contact Grinding

As a typical machining method of surface-contact grinding, honing is one of the best choices for the ultra-precision machining. Recently, many researchers's viewpoint of honing is that it's also an efficent material removal machining method, besides improving the surface structure of the inner hole. As a finishing operation, the surface quality of workpiece after honing is depended on the process parameters used. Because the surface quality of workpiece could affect the surface structure and tribological performance, it is important to study the material removal mechnism and surface generation. However, the research on this subject is not sufficient.Based on the grain motion paths, this thesis proposed a single grain mathematic model. Then combined with a honing stone model, a honing material removal model is set up. Honing angle, grain size, and honing pressure are analysed in this model to obtain the main factors that affect material removal. And a surface generation model is also proposed to study the surface quality. By means of many simulation experiments, this thesis analyses the influence of honing angle, grain size, and honing pressure on surface quality, especially on surface roughness.The models proposed in this thesis and the predicted results are verified by experiments did on a honing platform made by ourselves. In this thesis, a series of constant pressure honing experiments were did to analyse the influence on material removal and surface quality. In the machining process, Bauschinger effect is proved to exist by analysis on the experiment results. Besides, stone wear and honing force are also studied through experiments.The results in this thesis can not only be used to increase the processing efficiency, optimize parameters, and enhance the tribological performance, but also have a significant meaning in more general abrasive process.