Modeling And Experimental Verification Of Load Characteristics Of Disc Wheel In Abrasive Cutting Process

The abrasive cutting is widely used in machinery,metallurgy,mining,construction,automobile manufacturing and other industries.It could cut-off non-metallic materials and metallic materials,even parts of nonferrous metals in high rotation speed continuously.However,it is known that the abrasive cutting is a multipoint cutting process that affects the dimensional accuracy and disc lifetime.Since the diversity morphology of the disc wheel,the irregular distribution of abrasives and the uncertain of effective grains' number,it is difficult for the traditional identification methods to calculate the grinding force precisely,smoothly and efficiently.Therefore,describe the characteristics of grinding force in the grinding process detailedly and establish the calculation model of grinding force has important theoretical research value and engineering benefit to improve the machining accuracy,production efficiency as well as cost saving.Thus,the mainly work of this paper is as follows:(1)Design and improve the automatic feeding grinding wheel abrasive cutting device,set up the experimental system of abrasion cutting load.Design 5 feeding rate and 4 abrasion cutting rate to abrasion cutting experiment according to the characteristic of servo feed system and three phase AC asynchronous motor.(2)Establish the mathematical model of abrasion cutting load of disc wheel.Firstly,compose that the abrasion cutting force is composed by grinding force and cutting force.Then,considerate the single-grit morphology,grinding wheel and workpiece contact arc length,cutting depth as well as the integral distribution condition of several grit comprehensively,establish the mathematical model of grinding force and the mathematical model of cutting force.Thirdly,optimize the calculation of grinding force by introduce the abrasive height coefficient and the effective abrasive coefficient.Lastly,establish the mathematical model of abrasion cutting force.Simulation and test results show that:(a)Simplify the abrasives as rigid polyhedron,introduce the abrasive height coefficient,and combine the contact arc length.This paper propose and optimize the basic model of grinding force and reduce the simulation error by 10%.(b)Base on the probability statistical method,induce the effective abrasive coefficient,consider the effective grains' number synthetically,this paper establish the multi-particles grinding force calculation model and reduce simulation error by 5.6%.(c)It could be more precise to establish the multi-particles grinding force calculation model by considering the abrasive height coefficient and effective abrasive coefficient.Simulation and experiment error was not more than 7.8%.Therefore,the model precisely reflect the actual grinding process and provide good theoretical support of technical guidance for optimization of the process.