Research On The Grinding Force Of The Engineered Super-Hard Grinding Wheel

As an important processing method,grinding can achieve precision and ultraprecision machining of parts.So the grinding wheel is demanded more highly.The abrasives on the surface of the traditional super-hard grinding wheel are distributed randomly.In the process of grinding it will occurs a series of problems such as low abrasive utilization rate,higher grinding forces and grinding temperature and poor grinding quality.The above problems can be solved effectively by making the abrasives be engineered.And a new type of engineered grinding wheel is proposed based on the phyllotaxis theory which can improve the grinding performance.Firstly,the phyllotaxis theory is briefly introduced.A fly cutting is designed in order to study the grinding mechanism of grinding wheel.The fly cutting with four abrasive with different arrangement is fabricated by using the technology of lithography and composite electroplating.Secondly,the grinding force model of single abrasive is established by considering the material deformation.The number of the effective grains is counted in the process of grinding.The grinding force model of the whole grinding wheel is finally established by taking the abrasive wear into account.Thirdly,the experiment of grinding the titanium alloy TC4 was carried out by using the single abrasive and abrasive cluster grinding wheel with different patterns.The results show that under the same experiment conditions the grinding force of the grinding wheel with abrasive phyllotactic pattern is smaller than those grinding wheels with staggered and random pattern.Finally,the single abrasive scratch experiment is carried out by using the fly cutting with four abrasives with different arrangement in order to recognize the material deformation and the grinding mechanism.The results show that the deformation behavior of material is from sliding to the plough and finally producing the cutting with the increase of the grinding depth.And also the result show that during the process ofgrinding the cutting number of the fly cutting with phyllotactic pattern is more than that with staggered pattern and random pattern.So the grinding force of the fly cutting with phyllotactic pattern is smaller than the others according to the size effect.