平面磨削力建模及其应用研究

【作者】 陈勇平；

【导师】 唐进元； 李国顺；

【作者基本信息】 中南大学 ， 机械制造及其自动化， 2007， 硕士

【摘要】 磨削加工是精密和超精密加工的主要方法之一。磨削力对砂轮的磨损、工艺系统的变形、工件的表面加工质量等均有重大的影响。因此，建立能够预测磨削加工中磨削力大小的模型具有非常重要的意义。本文首先对磨削加工过程建模的研究进展和齿轮磨削研究领域近年来的研究动态做了较为详尽的比较研究，提出了本文研究工作的思路：从研究磨削加工中的尺寸效应机理出发，推导出平面磨削力计算公式，在此基础上，结合锥面砂轮磨齿原理，提出齿轮磨削力的计算公式。对国内外学者关于磨削加工中的尺寸效应机理方面所作的研究工作进行了分析综合，在此基础上把比磨削能分为比切削能和比滑擦能，分别对比切削能和比滑擦能的尺寸效应进行了分析，对磨削加工中的尺寸效应机理给出了较全面的解释。将磨削力分为切屑变形力和滑擦力两部分，建立了平面磨削中磨削力的数学模型，用实验数据验证了模型的有效性。在切屑变形力模型的建立过程中，提出将比切屑能分为静态比切屑能和动态比切屑能两部分，在动态比切屑能的研究中考虑了金属材料剪切去除过程中材料的剪应变效应、剪应变率效应和热软化效应的影响，通过分析比切屑能与切屑变形力的关系，得出了切屑变形力的计算公式；在滑擦力模型的建立过程中，在以往研究者的基础上，考虑了磨削工艺参数对摩擦系数的影响。基于锥面砂轮磨齿展成运动的几何模型，计算出砂轮在任意冲程中所磨除金属材料的几何形状尺寸，在平面磨削力计算公式的基础上对该被磨除金属材料沿磨削宽度方向进行积分，得到了齿轮磨削过程中磨削力的计算公式。更多还原

【Abstract】 Grinding is one of main methods used in the precision and superprecision manufacturing. Grinding force has great influence on the wear of grinding wheel, the deformation of technical system, the surface quality of workpiece, etc. Therefore, it is important to advance a model to predict the grinding force.The progresses on the modeling of grinding process and the gear grinding were analyzed. The research approach is established as follows: Firstly, research on the size effect in grinding process; secondly, deduce a formula for calculating the grinding force in surface grinding; lastly, advance a formula for calculating the grinding force in gear grinding combined with the principle of gear grinding.The advancement on the size effect in grinding process was studied. The specific grinding energy is divided into the specific cutting energy and the specific sliding energy. And those two specific energies were analyzed, respectively. The explanations to the size effect in grinding process are proposed.A new mathematical model of the grinding forces, which are composed of chip formation force and sliding force, in surface grinding is proposed. The comparison of the experiments and the calculations proves the effectiveness of the model. It is proposed that the chip formation energy is divided into the static chip formation energy and the dynamic chip formation energy. The dynamic chip formation energy is influenced by the shear strain, the shear strain rate and the heat in the metal removing process. A formula for calculating the chip formation force is given by analyzing the relationship between the chip formation energy and the chip formation force. And a formula for calculating the sliding force considering the influence of technologic parameters on friction coefficient is proposed based on the achievements of other researchers.The geometrical model of the gear grinding process was established. And the geometrical shape of the metal material, which was cut from the gear in any stroke of the cone-shaped grinding wheel, was calculated. A formula for calculating the grinding force in gear grinding process was obtained by integrating the formula for calculating the grinding force in surface grinding along the direction of the grinding width.更多还原