Establishment of dynamic grinding force model for ultrasonic-assisted single abrasive high-speed grinding

• Published in: Journal of materials processing technology 2022-02, Vol.300, p.117420, Article 117420
• Main Authors: Lei, Xiaofei, Xiang, Daohui, Peng, Peicheng, Liu, Gaofeng, Li, Bo, Zhao, Bo, Gao, Guofu
• Format: Article
• Language: English
• Subjects: Abrasive wear; Axial forces; Cast iron; Dynamic grinding force model; Grinding; High speed; Machining; Mathematical models; Nodular iron; Parameters; QT500-7 ductile cast iron; Single abrasive; Surface properties; Tool life; Ultrasonic-assisted grinding; Workpieces
• ISSN: 0924-0136; 1873-4774
• DOI: 10.1016/j.jmatprotec.2021.117420

In order to explore the influence of ultrasonic-assisted grinding on the grinding force in the machining process, a new dynamic grinding force model of ultrasonic-assisted single abrasive high-speed grinding is established based on the fact that the abrasive particles are constantly worn in the machining process. [Display omitted] In the grinding process, the magnitude of the grinding force has a serious impact on the surface quality of the workpiece and the tool life. In order to explore the influence of different grinding parameters on the grinding force in the ultrasonic-assisted grinding process, this paper carried out an ultrasonic-assisted single-grain high-speed grinding experiment. First, the forms of abrasive wear were analyzed, and the reasons for the formation of different abrasive wears were discussed. The results showed that the grinding force of a single abrasive increases with the increase of abrasive wear volume. In addition, based on the condition that the abrasive particles are constantly worn over time during the machining process, a new type of dynamic grinding force model for ultrasonic-assisted high-speed grinding of single abrasive particles was established based on the relationship of abrasive wear volume changes with time. The model was verified experimentally by ultrasonic-assisted single-grain grinding of QT500-7 ductile cast iron, and the change law of single-grain grinding force with time under different parameters was explored. It was found that under the same parameters, the axial force of a single abrasive particle is always greater than the tangential force, and the grinding force increases with the increase of workpiece linear speed. The maximum error between the experimental value and the simulated value of the grinding tangential force is about 34 %, and the maximum error of the normal force is about 23 %, but the variation trend of the two with time is basically the same.