虚拟磨削关键理论及其技术的研究
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摘要
磨削加工是机械制造中重要的加工工艺,通常被用于零件的最后一道加工工序,以获得光洁的加工表面和精确的公差,是目前应用最为广泛的高效、高精密加工工艺。磨削加工与车、铣等加工方法相比存在着巨大的优势,但是由于磨削工具的独特性,即砂轮表面上磨粒形状的不规则性、尺寸的不确定性、分布的随机性以及砂轮运动的高速性,使得对磨削加工机理的研究及磨削加工过程的预测分析较其它加工方法困难得多。
采用传统的解析法和实验法研究磨削过程都存在一定的弊端,解析模型的应用范围有限,而实验工作任务繁重。仿真法弥补了这两种方法的不足,是磨削加工研究的新方法。虚拟磨削加工技术的应用进一步扩展了磨削加工仿真研究的范围。虚拟的磨削过程使研究者能够更加直观地观察砂轮的磨削行为及材料的去除过程,从而有利于研究者对砂轮的磨削性能及加工质量做出准确的评价,因此,将虚拟磨削加工技术应用于磨削加工理论的研究极具实际意义。
本文采用虚拟磨削加工与实验相结合的方法,对磨削加工机理及虚拟磨削表面形貌系统的开发两个方面进行了较深入的研究。论文的研究工作主要包括以下几个方面：
(1)根据磨削加工的特点,确立了磨削物理仿真研究的数值模拟方法。分析了有限元法和光滑粒子流体动力学法的特点与适用范围,并通过仿真实例验证了其应用于磨削加工仿真研究的可行性。
(2)采用Lagrange/Euler耦合算法与Lagrange/SPH耦合算法分别进行了单颗CBN磨粒切削45钢的仿真研究。根据仿真结果分析了各自算法的优缺点,并选择最佳方法进行了不同加工参数下的单颗磨粒切削仿真,进而分析了磨粒的切削机理。
(3)考虑到砂轮表面上磨粒形状的不规则性、尺寸的不确定性、分布的随机性特点,构建了具有实际砂轮地貌特征的虚拟砂轮模型。采用该模型进行了磨削加工物理仿真,进而分析了砂轮的磨削特性及工件表面形貌的创成机理。
(4)采用光滑粒子流体动力学法模拟了CBN磨粒的磨耗、破碎过程。根据磨粒的磨损形态及断裂行为分析了CBN磨粒的磨损机理。
(5)基于虚拟现实技术理论,采用Visual C++编程软件及三维图形软件标准接口OpenGL开发了虚拟磨削表面形貌系统。以正六面体作为磨粒的基本形态,将其随机分布在砂轮基体表面上,建立了虚拟砂轮模型；建立了虚拟磨粒与工件的干涉计算模型。以平面磨削为例,进行了不同加工参数下的磨削仿真,进而测试了虚拟砂轮的磨削性能,并分析了磨削加工参数对工件表面粗糙度的影响。
(6)采用超高速陶瓷CBN砂轮贴片样块,设计了磨粒划擦实验、砂块磨削实验及砂块磨损实验。通过比较实验结果与仿真结果,初步验证了单颗磨粒切削仿真、虚拟砂轮建模及其加工仿真、砂轮磨损仿真的正确性。
Grinding is an important processing technology in the machinery manufacturing industry. It is often used in the last manufacturing procedure for achieving smooth surface and precise tolerance. It is currently the most used high-performation, high precision processing technology. Grinding is superior to cutting such as turning and milling in some respects, but grinding process is much more complex than cutting process owing to its unique grinding tool. The abrasive grains on grinding wheel have no fixed shape and size, and their distribution is also irregular. Grinding wheel works in high speed. So the study on grinding mechanism and the prediction for grinding results are more difficult than some cutting process.
Analysis and experimentation are traditional method in the research of grinding, but they both have some shortcomings. Analytical model is based on assumption, so its application is limitied. Experimentation is tedious. Simulation is a new research method of grinding. It makes up for the two methods'shortcomings. Virtual grinding is a more advanced simulation for grinding. The researcher can intuitively observe grinding behavior of wheel and removing process of workpiece material. It is conducive for reasearcher to make accurate evaluation for the performation of wheel and processing quality. So, its application in the research of grinding has great practical significance.
Grinding mechanism and development of grinding simulation software are deeply researched by virtual grinding method and experimentation in this paper. The research tasks of the paper are as follows:
(1) According to the characteristics of grinding process, Numerical simulation methods suitable for the grinding simulation are chosed. The characteristics and application scope of Finite Element Method (FEM) and Smoothed Particle Hydrodynamics (SPH) are analyzed. The feasibility of their application in the research of grinding is verified by grinding simulation examples
(2) 45 steel cutting with single grain are simulated by Fluid-Solid-Interaction Method and Smoothed Particle Hydrodynamics respectively. Advantages and disadvantages of the two methods are compared. The cutting processes of single grain with different cutting parameters and orthogonal rakes are simulated by Smoothed Particle Hydrodynamics method. The mechanism of chip formation of single grain is analyzed according to the simulation results.
(3) The abrasive grains have no fixed shape, size and distribution. Considering these, topography of the grinding wheel is modeled. The model is basically consistent with the actual topography of the grinding wheel. Physical process of grinding is simulated with the model. Then, the performations of the wheel and formation mechanism of workpiece surface are analyzed.
(4) The processes of the rubbing and fracture of CBN abrasive are simulated by Smoothed Particle Hydrodynamics method. According to the dynamic simulation, the wear mechanism of CBN abrasive is analyzed.
(5) Based on Virtual Reality Technology, virtual grinding surface system is developed by Visual C++ and OpenGL. Takes ortho-hexahedron as basic shape of abrasive grain and distribut it randomly on the grinding wheel base, then virtual grinding wheel is modeled. Interaction model of abrasive grain workpiece is also modeled. Takes surface grinding as an example, grinding processes with different machining parameters are simulated. Grinding performance of virtual grinding wheel is tested. Influencing factors of formed surface roughness were analyzed.
(6) In order to verify the correctness of the single abrasive cutting simulation, the wheel model and its grinding simulation and abrasive wear simulation, scratching experiment, grinding experiment and wear experiment are made By using abrasive block of ultra-high speed vitrified bonded CBN wheel.
采用传统的解析法和实验法研究磨削过程都存在一定的弊端,解析模型的应用范围有限,而实验工作任务繁重。仿真法弥补了这两种方法的不足,是磨削加工研究的新方法。虚拟磨削加工技术的应用进一步扩展了磨削加工仿真研究的范围。虚拟的磨削过程使研究者能够更加直观地观察砂轮的磨削行为及材料的去除过程,从而有利于研究者对砂轮的磨削性能及加工质量做出准确的评价,因此,将虚拟磨削加工技术应用于磨削加工理论的研究极具实际意义。
本文采用虚拟磨削加工与实验相结合的方法,对磨削加工机理及虚拟磨削表面形貌系统的开发两个方面进行了较深入的研究。论文的研究工作主要包括以下几个方面：
(1)根据磨削加工的特点,确立了磨削物理仿真研究的数值模拟方法。分析了有限元法和光滑粒子流体动力学法的特点与适用范围,并通过仿真实例验证了其应用于磨削加工仿真研究的可行性。
(2)采用Lagrange/Euler耦合算法与Lagrange/SPH耦合算法分别进行了单颗CBN磨粒切削45钢的仿真研究。根据仿真结果分析了各自算法的优缺点,并选择最佳方法进行了不同加工参数下的单颗磨粒切削仿真,进而分析了磨粒的切削机理。
(3)考虑到砂轮表面上磨粒形状的不规则性、尺寸的不确定性、分布的随机性特点,构建了具有实际砂轮地貌特征的虚拟砂轮模型。采用该模型进行了磨削加工物理仿真,进而分析了砂轮的磨削特性及工件表面形貌的创成机理。
(4)采用光滑粒子流体动力学法模拟了CBN磨粒的磨耗、破碎过程。根据磨粒的磨损形态及断裂行为分析了CBN磨粒的磨损机理。
(5)基于虚拟现实技术理论,采用Visual C++编程软件及三维图形软件标准接口OpenGL开发了虚拟磨削表面形貌系统。以正六面体作为磨粒的基本形态,将其随机分布在砂轮基体表面上,建立了虚拟砂轮模型；建立了虚拟磨粒与工件的干涉计算模型。以平面磨削为例,进行了不同加工参数下的磨削仿真,进而测试了虚拟砂轮的磨削性能,并分析了磨削加工参数对工件表面粗糙度的影响。
(6)采用超高速陶瓷CBN砂轮贴片样块,设计了磨粒划擦实验、砂块磨削实验及砂块磨损实验。通过比较实验结果与仿真结果,初步验证了单颗磨粒切削仿真、虚拟砂轮建模及其加工仿真、砂轮磨损仿真的正确性。
Grinding is an important processing technology in the machinery manufacturing industry. It is often used in the last manufacturing procedure for achieving smooth surface and precise tolerance. It is currently the most used high-performation, high precision processing technology. Grinding is superior to cutting such as turning and milling in some respects, but grinding process is much more complex than cutting process owing to its unique grinding tool. The abrasive grains on grinding wheel have no fixed shape and size, and their distribution is also irregular. Grinding wheel works in high speed. So the study on grinding mechanism and the prediction for grinding results are more difficult than some cutting process.
Analysis and experimentation are traditional method in the research of grinding, but they both have some shortcomings. Analytical model is based on assumption, so its application is limitied. Experimentation is tedious. Simulation is a new research method of grinding. It makes up for the two methods'shortcomings. Virtual grinding is a more advanced simulation for grinding. The researcher can intuitively observe grinding behavior of wheel and removing process of workpiece material. It is conducive for reasearcher to make accurate evaluation for the performation of wheel and processing quality. So, its application in the research of grinding has great practical significance.
Grinding mechanism and development of grinding simulation software are deeply researched by virtual grinding method and experimentation in this paper. The research tasks of the paper are as follows:
(1) According to the characteristics of grinding process, Numerical simulation methods suitable for the grinding simulation are chosed. The characteristics and application scope of Finite Element Method (FEM) and Smoothed Particle Hydrodynamics (SPH) are analyzed. The feasibility of their application in the research of grinding is verified by grinding simulation examples
(2) 45 steel cutting with single grain are simulated by Fluid-Solid-Interaction Method and Smoothed Particle Hydrodynamics respectively. Advantages and disadvantages of the two methods are compared. The cutting processes of single grain with different cutting parameters and orthogonal rakes are simulated by Smoothed Particle Hydrodynamics method. The mechanism of chip formation of single grain is analyzed according to the simulation results.
(3) The abrasive grains have no fixed shape, size and distribution. Considering these, topography of the grinding wheel is modeled. The model is basically consistent with the actual topography of the grinding wheel. Physical process of grinding is simulated with the model. Then, the performations of the wheel and formation mechanism of workpiece surface are analyzed.
(4) The processes of the rubbing and fracture of CBN abrasive are simulated by Smoothed Particle Hydrodynamics method. According to the dynamic simulation, the wear mechanism of CBN abrasive is analyzed.
(5) Based on Virtual Reality Technology, virtual grinding surface system is developed by Visual C++ and OpenGL. Takes ortho-hexahedron as basic shape of abrasive grain and distribut it randomly on the grinding wheel base, then virtual grinding wheel is modeled. Interaction model of abrasive grain workpiece is also modeled. Takes surface grinding as an example, grinding processes with different machining parameters are simulated. Grinding performance of virtual grinding wheel is tested. Influencing factors of formed surface roughness were analyzed.
(6) In order to verify the correctness of the single abrasive cutting simulation, the wheel model and its grinding simulation and abrasive wear simulation, scratching experiment, grinding experiment and wear experiment are made By using abrasive block of ultra-high speed vitrified bonded CBN wheel.
引文
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