An investigation of the surface waviness features of ground surface in parallel grinding process
An investigation of the surface waviness features of ground surface in parallel grinding process
复制标题
平行磨削过程中磨削表面表面波纹度特征的研究
DOI：
10.1016/j.ijmecsci.2019.105351
复制
发表时间：
2020-03-15
影响因子：
7.3
通讯作者：
Wu, Xiaoqiao
中科院分区：
文献类型：
--
作者：
Pan, Yongcheng;Zhao, Qingliang;Wu, Xiaoqiao
用于玻璃成型的高精度碳化钨、碳化硅光学模具刀片通常采用超精密磨削加工，但表面波纹度残差难以消除。本文主要研究了平行磨削过程中与砂轮跳动误差和非整数转速比有关的表面波纹度特征。在综合考虑磨削运动学和微观材料去除的基础上，揭示了表面波纹特征的产生机理和分布趋势。为了模拟平行接地元件的表面波纹形貌，建立了适用于整型和非整型RSR的数学模型，并进行了实验验证。此外，还解释了RSR为非整数时表面波纹度降低的机理，这是由于砂轮二次磨削区再次去除材料所致。建立了基于波纹度轮廓重叠效应的表面波动度周期特征(SWPF)和表面波动度幅度特征(SWAF)预测模型，并进行了实验验证。研究发现，非整数RSR引起的波移对表面波纹度特征有显著影响。最后，提出了一种通过适当调整砂轮转速来减小平行磨削零件表面波纹度误差的简便方法，以实现适当的非整数RSR和波移，该方法对平面零件和菲涅耳零件都是可行和有效的。
The high precision tungsten carbide (WC) and silicon carbide (SiC) optical mold inserts used in glass molding are usually machined by ultra-precision grinding, but the residual surface waviness error is difficult to be eliminated. This paper mainly focused on the surface waviness features related to the grinding wheel run-out error and the non-integer rotation-speed-ratio (RSR) in parallel grinding process. After the integrate consideration of grinding kinematics and microscopic material removal, the generation mechanism and distribution trend of surface waviness features were revealed. In order to simulate the surface waviness topography of parallel ground components, a mathematical model was developed and experimentally proved, which was appropriate for both integer and non-integer RSR. Besides, the mechanism of surface waviness reduction was explained when RSR was non-integer, which was due to the material removal again by the secondary grinding zone of grinding wheels. Then prediction models for the surface-waviness-period-feature (SWPF) and surface-waviness-amplitude-feature (SWAF) was built and experimentally verified, which was based on the waviness profiles overlapping effect. It found that the wave-shift resulted from the non-integer RSR had significant influence upon the surface waviness features. In the end, a convenient method was proposed to reduce the surface waviness error of parallel ground components through proper adjustment of grinding wheel rotation speed to achieve proper non-integer RSR and wave-shift, which was proved practically feasible and effective for both plane components and Fresnel components.