面向硬脆材料高质高效加工的耦合仿生宏微结构砂轮设计与其磨削机理研究

结构化金刚石砂轮磨削工艺以其增效抑损延寿等特点在硬脆材料加工中得到日益广泛的应用，但该方法目前仍存在宏微结构不兼备、设计缺乏规律性指导和间歇瞬时热-力强场作用下磨削机理尚不明确等技术瓶颈，其高质高效化加工受到极大限制。本项目提出耦合仿生宏微结构金刚石砂轮设计新思路与间歇瞬时热-力强场作用下磨削机理研究新视角。揭示宏微结构表征参数-砂轮储运排屑和减摩抗磨性能-仿生耦元协同作用机制的内在关联，建立金刚石砂轮表面宏微结构的耦合仿生设计理论。阐明磨削区热力相关要素-微区材料特性-材料去除与损伤-砂轮磨损与失效的关联规律，建立硬脆材料新型临界磨削深度、亚表面损伤深度和工具寿命的完整实用预测模型。构建耦合仿生宏微结构金刚石砂轮设计与磨削加工基础理论体系，实现硬脆材料的高质高效加工。本项目对于促进表面结构化金刚石砂轮的推广应用、提升硬脆材料精密零部件的制造水平具有重要的科学意义和应用价值。

Due to the superior characteristics in terms of increased efficiency, suppressed surface/subsurface damages and extended wheel life, the surface structured diamond wheel has been widely used in grinding hard and brittle materials. However, the technological difficulties for the incomplete macro-micro structures, irregular design and unclear grinding mechanism under the action of intermittent and instantaneous thermo-mechanical field have never been solved. Its high-quality and high-efficient processing is greatly limited. To fill this gap, a new design concept of coupled bionic macro-micro structures diamond wheel and a new research direction of grinding mechanism under the action of intermittent and instantaneous thermo-mechanical field are proposed. The internal relation among the characterization parameters of the macro-micro structures, the liquid-storage, chip-removal, friction-reduction and wear-resistant performance of grinding wheel, and the synergistic effect between bionic coupling elements will be revealed. Then the coupled bionic design theory of the surface macro-micro structures of the diamond wheel will be established. In addition, the correlation among the thermo-mechanical related elements in the grinding zone, local characteristics of hard and brittle material, material removal and surface/subsurface damages, and wear and failure of grinding wheel will be clarified. Subsequently, a series of complete and practical prediction models including subsurface damage depth and ductile grinding threshold of the hard and brittle materials, as well as tool life of diamond wheel will be established. Furthermore, the design of the coupled bionic macro-micro structures diamond wheel and the basic grinding theoretical system will be established, which is beneficial to achieve the processing of hard and brittle materials with high-quality and high-efficient. The research achievement of this proposed project will promote the application of the surface structured diamond wheel and improve the manufacturing level of hard and brittle materials precision parts from the point of scientific significance and application value.