Study On Ultrasonic Assisted Grinding Mechanism And Surface Quality Of Cone Wheel

Conventional grinding(CG)has many problems,such as low efficiency,poor surface quality and surface defects,which greatly limit the practical application of processed materials.As an effective machining method,ultrasonic vibration assisted grinding(UVAG)has great advantages in reducing cutting force,improving surface quality and reducing the formation of surface defects compared with CG.There are various processing parameters involved in the process of ultrasonic assisted grinding,such as wheel speed,ultrasonic frequency,ultrasonic amplitude,grinding depth,etc.In order to obtain reasonable processing parameters,this paper takes 45# steel sample as the research object and studies the generation mechanism and material removal mechanism of intermittent grinding and non-intermittent grinding from the grinding mechanism.A theoretical model of material removal volume was established,and the influence of different grinding parameters on surface topography and surface roughness was discussed by finite element simulation and experiment.Specific research contents are as follows:1.Firstly,kinematic analysis of a single abrasive particle on the grinding wheel surface was carried out from the microstructure,and the kinematic equation of single abrasive particle was established.Based on the kinematic relationship between the abrasive particle and the workpiece being processed,the cutting arc length of a single abrasive particle under non-intermittent grinding and intermittent grinding modes was established,and then the removal volume model of a single abrasive particle under two grinding modes was established.On this basis,the relationship between grinding depth and machining parameters was obtained according to the equal macroscopic volume and microscopic volume.2.The assembly model of grinding wheel and workpiece was established,and the finite element analysis was carried out on the ultrasonic assisted grinding process of single row abrasive.The effects of different ultrasonic grinding parameters(wheel speed,ultrasonic amplitude,grinding depth)on the surface topography of nonintermittent grinding were investigated by designing a single factor simulation test.The secondary development of Abaqus was used to calculate the roughness of the simulated surface directly,and the roughness under different grinding parameters was analyzed.It was proved that the finite element simulation secondary development program was feasible to predict the surface roughness trend.3.The processing conditions of intermittent ultrasonic grinding were formed by finite element simulation.The simulation experiment of intermittent grinding was designed and carried out,and the ultrasonic grinding test bench was set up to carry out the actual machining under the same parameters.The change rule of surface topography was observed and analyzed by metallography microscope.The arc length of the real machined surface was measured and the theoretical model of arc length was verified by combining the simulation results.