基于化学机械效应的单层超硬磨料砂轮临界干涉修整技术基础研究

To solve the problem of the poor surface quality due to the poor accordance of the exposure height of grains of the monolayer superabrasive wheels, the mechanical dressing method combined with the allotropic transformation of the superabrasive grains and the accompanied chemical reaction is put forward. Based on this dressing process, the inefficiency of the existing dressing process and the low grinding efficiency after dressing process could be conquered, which have hindered the wide application of the dressing technology of monolayer superabrasive wheels in high efficiency grinding. After dressing, the over-height part of the grains could be removed away and the sharp cutting edge of the grains remained. As a consequence, not only the high machining efficiency of monolayer superabrasive wheels could be improved but also the same workpiece quality could be achieved as the multilayer vitrified, metal-bond and resine-bond superabrasive wheels. In this project, the main contents are as follows: the allotropic transformation mechanism of the superabrasive grains and the accompanied chemical reaction mechanism, critical intervening dressing mechanism of monolayer superabrasive grains, characterization of the dressed wheels based on critical intervening dressing process. The significance of this project is not only to improve the surface quality, but the most important is to guarantee the tool support considering both the high machining efficiency and the high surface quality to lead the development of high speed grinding technology.

针对单层超硬磨料砂轮磨粒等高性差的固有缺陷，以及由此带来的磨削加工表面质量差的问题，提出将超硬材料向其同素异构体转变及伴随的化学反应过程与机械修磨法有机结合，解决现有修整技术本身存在的低效率和修整后砂轮磨削效率降低的问题，高效地去除砂轮上磨粒过度突出部分，并保有砂轮磨粒锋利的切削刃，赋予单层超硬磨料砂轮在发挥其高加工效率的同时，可获得与陶瓷结合剂、金属结合剂及树脂结合剂等超硬磨料砂轮同等加工表面质量的新属性。项目主要研究超硬磨料同素异构转变及其伴随化学反应机制、单层超硬磨料砂轮临界干涉修整机理、基于临界干涉修整的单层超硬磨料砂轮磨削性能表征等关键问题。项目研究的意义不仅在于改善了单层超硬磨料砂轮磨削表面粗糙度差的问题，更重要的是为引领磨削技术发展的高速磨削研究领域提供了能够兼顾磨削效率和加工表面质量的关键工具保障。

项目针对单层超硬磨料砂轮磨料等高性差的固有缺陷，提出了基于机械化学综合效应的单层超硬磨料砂轮临界干涉修整新方法，有效去除了砂轮上磨粒过度突出部分，提高了超硬磨料砂轮加工的表面质量和加工效率。主要开展的研究内容包括：.（1）以单颗磨粒磨损为基础，研究了机械化学效应对去除单层金刚石砂轮过度突出部分磨粒尖端的影响，分析了去除机理，探讨了对磨削过程的影响，为修整方法的建立提供了基础。.（2）设计制造了基于机械化学效应的临界干涉修整装置，开展了单层钎焊金刚石砂轮的临界干涉修整试验，提高了单层金刚石砂轮的等高性，使硬脆材料的磨削加工表面粗糙度的到有效提高，实现了采用80/100与40/50目粗颗粒单层金刚石砂轮获得碳化硅、玻璃等硬脆材料的镜面磨削表面。.（3）系统评价修整条件、磨削工艺条件对碳化硅、玻璃磨削表面粗糙度、加工表面/亚表面损伤的影响，建立了修整量-磨粒等高性-磨削质量间的关联关系，对基于机械化学修整的单层钎焊金刚石砂轮磨削性能进行了综合评价。.（4）提出了单层钎焊CBN成型砂轮的超高频连续感应钎焊新方法，从砂轮制造的角度，控制的砂轮基体精度和磨粒分布，为单层CBN砂轮满足航空发动机叶片榫头的成型磨削精度与粗糙度提供了技术基础。.（5）将建立的砂轮临界干涉修整技术移植到多层陶瓷结合剂CBN砂轮修整中，建立了多层陶瓷结合剂CBN砂轮修整的新方法，为解决采用传统滚轮修整工具寿命低，修整效果差的问题，提供了新途径。.项目完成了计划书的研究内容，达到了预期目标。项目已发表研究论文15篇，授权发明专利2项，申请发明专利3项，培养研究生7人。