| CHU Shuai-zhen,NIU Ying,WANG Zhuang-fei,JIAO Feng.Prediction and Experiment on Surface Morphology of Longitudinal- torsional Ultrasonic Grinding of GCr15 Shaft Sleeve[J],52(9):294-305, 339 |
| Prediction and Experiment on Surface Morphology of Longitudinal- torsional Ultrasonic Grinding of GCr15 Shaft Sleeve |
| Received:November 12, 2022 Revised:March 17, 2023 |
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| DOI：10.16490/j.cnki.issn.1001-3660.2023.09.025 |
| KeyWord:GCr15 shaft sleeve elastic deformation longitudinal torsional ultrasonic grinding surface morphology model surface roughness |
| Author | Institution |
| CHU Shuai-zhen |
School of Mechanical and Power Engineering, Henan Polytechnic University, Henan Jiaozuo , China |
| NIU Ying |
School of Mechanical and Power Engineering, Henan Polytechnic University, Henan Jiaozuo , China |
| WANG Zhuang-fei |
School of Mechanical and Power Engineering, Henan Polytechnic University, Henan Jiaozuo , China |
| JIAO Feng |
School of Mechanical and Power Engineering, Henan Polytechnic University, Henan Jiaozuo , China |
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| Abstract: |
| In order to establish a surface morphology model of longitudinal-torsional ultrasonic grinding (LTUG), analyze the effect of process conditions and parameters on surface roughness Ra value, and reveal the formation mechanism of internal surface of GCr15 shaft sleeve during LTUG. Firstly, a motion trajectory model of a single abrasive grain in LTUG was established. Combined with the number of vibrations of the abrasive grains in the grinding time, the grinding arc length of a single abrasive grain in the grinding area was obtained. Then, based on the effect of elastic deformation between the grinding wheel grain and the workpiece on the movement track of a single abrasive grain in longitudinal-torsional ultrasonic grinding, according to the probability density function of cutting thickness, the maximum undeformed cutting thickness model of a single abrasive grain under longitudinal torsional ultrasonic vibration was established. Considering the overlapping effect of adjacent abrasive grain motion tracks, the maximum undeformed cutting thickness model under the action of multiple abrasive grains was established. Finally, a morphology prediction model of GCr15 shaft sleeve internal grinding was established using the surface residual material height. The reliability of the morphology model was verified by orthogonal tests of four factors and three levels. Several groups of tests were conducted on the inner ring of GCr15 shaft sleeve by LTUG and ordinary grinding (OG). The surface Ra value of GCr15 shaft sleeve under different grinding methods was observed and analyzed with a field microscope of super depth. The grinding surface Ra value under different amplitudes was simulated and its contour lines were extracted based on established surface morphology model. The actual surface Ra value was observed with a confocal microscope and its contour lines were extracted. The grinding simulation contour and the actual contour were compared and analyzed. The effect of process parameters on the surface Ra value was investigated using the single-factor test method. The results of the orthogonal tests showed that the errors of the test results and the prediction model were within 13.2%. Compared with the OG, there were more uniform surface groove wear marks under LTUG; the surface profile of OG was complex and irregular, but the surface profile of LTUG fluctuated regularly and periodically, and the distance between the peaks of the surface profile increased with the increase of amplitude; Compared with ordinary grinding, with the increase of wheel speed, the surface Ra value of LTUG decreased from 12% to 19.6% and then to 13.7%, with the increase of grinding depth, the surface Ra value of LTUG decreased from 19.2% to 11.9%, with the increase of feed speed, the surface Ra value of LTUG decreased from 14% to 8.1%, and with the increase of workpiece rotation speed, the percentage of surface Ra value reduction in LTUG decreased from 14% to 11.1% and then to 13.6%. In both grinding modes, compared with OG, the surface Ra value under LTUG was always lower than that of OG, and the maximum reduction of surface Ra value was 20%. With the increase of ultrasonic amplitude, the surface Ra value decreased gradually, but when the ultrasonic amplitude increased to a certain extent, the surface Ra value tended to increase. The LTUG surface morphology prediction model established in this paper has good accuracy, under appropriate process parameters, LTUG can significantly reduce surface Ra value, compared with OG, the length of abrasive motion track under LTUG is longer, and the elastic deformation in LTUG area has different effects on abrasive motion track and maximum undistorted cutting thickness. |
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