Study On Preparation Process And Processing Technology Of Irregular Intermittent Micro-grinding Tools

With the continuous development of industrialization,people's demand for micro-component products has become larger and larger.In the process of production and processing,in order to improve the accuracy and surface quality of products,micro-grinding has attracted more and more attention.It is currently an important research method to achieve high precision and high surface quality of micro-parts and micro-structure components.However,there are limitations in chip removal and heat dissipation in the micro-grinding process of ordinary micro-abrasive tools.Therefore,two different types of intermittent micro-abrasive tools are proposed and designed in this paper to solve the above problems.First of all,this paper proposes and designs two different types of intermittent micro-abrasive tools,straight and spiral.The grinding mechanism of intermittent micro-grinding tools is different from that of ordinary cylindrical micro-grinding.Due to the existence of invalid grinding zones,the abrasive particles and the workpiece are in discontinuous contact during the grinding process.In addition,the material removal model of discontinuous micro-abrasive tools and the micro-grinding force model of spiral discontinuous micro-abrasive tools and straight discontinuous micro-abrasive tools were established by considering the height of the abrasive particles.In order to verify the accuracy of the mechanical model and the superiority of the designed intermittent micro-grinding tool,a series of single-factor micro-grid comparative experiments were carried out in this paper.It has been proved through experiments that the grinding force of the intermittent micro-grinding tool is significantly smaller than that of the ordinary cylindrical micro-grinding tool.In addition,with the increase of the feed rate,the grinding force amplitude and the fluctuation degree of the grinding force of the ordinary cylindrical micro-grinding tools are larger than the intermittent micro-grinding tools.The results of different micro-abrasives machining workpieces were analyzed and compared.As the intermittent micro-abrasive tool has a good capacity for chip removal and chip removal,with the increase of the feed rate,the surface quality of the workpiece processed by the intermittent micro-abrasive tool is better than that of ordinary micro-abrasive tools.The established mechanical model is verified based on experimental data.The micro-grinding force model of different intermittent micro-grinding tools established in this paper can well predict the micro-grinding force generated by actual machining.The error between the measured value of the grinding force and the calculated value of the established mechanical model is within a controllable range,especially as the feed rate increases,the error becomes smaller and smaller.This article further compares the four discontinuous micro-abrasive tools designed from the aspects of abrasive wear,surface quality of the workpiece and grinding force.It is concluded that the four-slot spiral discontinuous micro-abrasive tools have the best grinding performance.Finally,a series of single-factor experiments are designed for four-slot spiral discontinuous micro-abrasive tools for processing different materials.The surface quality of different materials after processing is analyzed,and the details of the average grinding force and grinding force of the x-axis direction and y-axis direction produced by different materials during the grinding process are analyzed and compared.The obtained carbon fiber composite material has the best surface quality after processing,meanwhile,the average grinding force is the smallest,and the grinding detail force fluctuation is the most stable.The conclusion of this study provides theoretical reference and experimental basis for micro-grinding of discontinuous grinding tools.