Ultra-High Speed Surface Grinding with cBN Wheel at a Wheel Speed of 500 m/s

一个高频率轮子的螺旋桨，用于超高速表面研磨机已经开发出来。这个项目的目标是实现一个高效率的钢与cBN轮子研磨，在一个存货剥离率超过300 mm^3/（mm·s）的车轮外围速度为400 m/s。在这样的速度下，空气和凉爽的幻想导致的能量损失大于研磨的力量。首先，对研磨力的理论分析被证明是为了估计研磨力。From this analysis the wheel diameter of F250mm and motor power of 22 kW at 30000 min^\-1> were decided。此外，FEM的一项特征值分析表明，以确定螺旋轴的直径，该直径轴被一个重型车轮所抵消。在螺旋单元中，一种新开发的润滑剂减少了无负荷功率和轴承的温度上升。更远，一个恒定的预装载机制被采用，可以在不烧掉轴承的情况下实现高硬度。最后，一个小直径轮子的优势 ... More 根据对空气Friction损失的测量，证实了使用逻辑法计算的结果。第二，超高速研磨（UHSG）机器能够开发出400米/秒的车轮速度。UHSG是一种高效率的机器方法。它已经到达了舞台的地方，它可以完美地满足对机器效率的期望，即使用切割方法进行比较。USHG的概念并不新，但UHSG的实际应用是如何在超高速旋转中解决研磨轮和车轮螺旋单元的制造问题的一个困难。在先前的工作中，一个超高速旋转单元（30，000转速，22千瓦，2*10^6 dn值）已经开发出来。在本文中，使用设计和制造的螺旋单元的UHSG机器。振动、噪音和冷却的摩擦损失的机器被测量并与传统的研磨结果相比较。UHSG测试在300米/秒的速度下运行，使用开发的机器和一个合格的绑定cBN轮子。cBN轮子有一个CFRP核心是专门设计的。然而，在UHSG的区域内，冷却供应是不够的，因此需要开发一种低成本供应方法。Less（低）

A high-frequency wheel spindle for an ultra-high speed surface grinding machine was developped. This project aims to achieve a high efficiency grinding of steel with cBN wheels, in which a stock removal rate is over 300 mm^3/(mm・s) at a wheel peripheral speed of 400m/s. At such a speed, the power loss caused by air and coolant friction is larger than grinding power. At first, a theoretical analysis of grinding forces was carried out to estimate the grinding power. From this analysis the wheel diameter of F250mm and motor power of 22 kW at 30000 min^<-1> were decided. Also, an eigenvalue analysis by FEM was carried out to decide the diameter of the spindle shaft that avoids the resonance caused by a heavy wheel. In the spindle unit, a newly developed lubrication reduces the no-load power and the temperature rise of bearings. Furthermore, constant pre-load mechanism was adopted to achieve a high stiffness without burning out the bearings. Finally, the advantage of a small diameter wheel … More is confirmed experimentally by measurement of air friction loss, which confirmed to calculated results using the logarithmic law.Secondly, an ultra-high speed grinding (UHSG) machine which is capable of 400m/s wheel speed was developped. UHSG is one of the high efficiency machining methods. It has reached the stage where it can complete well with respects to machining efficiency even in comparison with a cutting method. Concept of the USHG is not new, however a practical application of the UHSG was difficult due to the manufacturing problems of a grinding wheel and a wheel spindle unit in the ultra-high speed rotation. In the previous work, an ultra-high speed spindle unit (30000 rpm, 22kW,2*10^6 dn-value) was developed. In this paper, a UHSG machine using the spindle unit was designed and manufactured. Vibration, noise and coolant friction loss of the machine were measured and compared with the conventional grinding results. The UHSG tests were performed under the 300m/s wheel speed using the developed machine and a vitrified bonded cBN wheel. The cBN wheel having a CFRP core was specially designed. However, coolant supply was not enough in the region of the UHSG,therefore the development of a low friction supplying method was needed. Less