混合仿生微结构化超硬磨料成形砂轮的水导激光制备与磨削机理研究

成形磨削工艺是齿轮、涡轮叶片、整体式刀具等复杂曲面零部件的重要加工手段。针对成形磨削高温易导致工件表面热损伤瓶颈，本项目提出微结构化超硬磨料砂轮成形磨削新工艺，并提出成形砂轮表面微结构的混合仿生设计新思路与水导激光制备新方法。揭示微结构表征参数-砂轮储液减摩性能-砂轮换热抗磨性能的内在关联，建立砂轮表面微结构的混合仿生设计理论。揭示砂轮表面微结构的形性调控机理，阐明水导激光工艺参数对砂轮表面微结构表征参数与地质地貌的影响规律，掌握微结构化成形砂轮水导激光可控制备技术。揭示微结构化成形砂轮磨削热损伤的产生与演化机理，阐明磨削工艺参数-磨削力与温度-工件表面完整性与轮廓精度的关联规律，建立微结构化超硬磨料成形砂轮磨削加工理论，突破难加工材料复杂曲面磨削热损伤瓶颈。本项目对于推广结构化砂轮工业应用、提升复杂曲面零部件磨削表面完整性具有重要科学意义与应用价值，同时有利于促进机械制造业的可持续发展。

The profile grinding process is an important processing method for complex curved parts such as gears, turbine blades and integral cutting tools. Aiming at the bottleneck that the high temperature is likely to cause thermal damage on the surface of the workpiece during the profile grinding, a new process for profile grinding using microstructured superabrasive grinding wheels is proposed, and a new idea of mixed bionic design and a new method of water-jet guided laser preparation for the surface microstructure of the profile grinding wheel are proposed. The internal relation among the characterization parameters of the microstructure, the liquid-storage and friction-reduction performance of the grinding wheel, and the heat-transfer and wear-resistance performance of the grinding wheel will be revealed, and the mixed bionic design theory of the surface microstructure of the grinding wheel will be established. The control mechanism of the shape and performance of the surface microstructure of the grinding wheel will be revealed. The influence of water-jet guided laser process parameters on the microstructured characterization parameters and topography of the grinding wheel’s surface will be clarified, and the water-jet guided laser preparation technology of microstructured profile grinding wheels will be mastered. The mechanism of the generation and evolution of thermal damage during the profile grinding using microstructured grinding wheels will be revealed, and the correlation among the grinding process parameters, the grinding force and temperature, the surface integrity and contour accuracy of the workpiece will be clarified. The grinding theory of the microstructured superabrasive profile grinding wheel will be established, and then the bottleneck of grinding thermal damage to complex surfaces of difficult-to-cut materials will be broke. This project has important scientific significance and application value for promoting the industrial application of structured grinding wheels and improving the ground surface integrity of complex curved parts, and is conducive to promoting the sustainable development of machinery manufacturing.