硬脆材料高效磨削工艺系统稳定性的多维交互机理研究

Grinding process system is the unity of grinding machine, fixture, tool and workpiece, the pros and cons of its dynamic performance has played a vital role in grinding stability. For the sake of the existence of instable grinding process, instable product precision and surface quality and low machining efficiency, this project takes the grinding of hard brittle material as the research object, high efficiency and stable grinding as the breakthrough point. In this project, the common feature of the grinding stability of the hard brittle material and the modeling method of the technology of system dynamics are explored, the multi-dimensional interaction mechanism of process system stability is studied. The coupling interaction strategy is adopted to establish the model of multi-dimensional interaction process system and the identification model which is based on the stability of the multi-dimensional interaction of grinding process system. A set of security stable efficient grinding of hard brittle material parts digital modeling, and multi-dimensional interactive algorithm and process parameters optimization methods is put forward. The results of this project play great importance in illustrating the multi-dimensional interaction mechanism and the complex response mechanism of grinding stability. Therefore, the theoretical and technical support is provided for high efficiency and high quality grinding of hard brittle materials.

磨削工艺系统是磨床、夹具、工具和工件的统一体，其动态性能的优劣对磨削稳定性起到了至关重要的作用。本项目针对硬脆材料零件磨削过程中存在的加工过程不稳定、产品精度与表面质量不稳定、加工效率低等问题，以磨削硬脆材料的工艺系统为研究对象，以高效稳定磨削为切入点，探索硬脆材料磨削稳定性的共性表征和工艺系统动力学建模方法，研究硬脆材料磨削工艺系统稳定性的多维交互机制，采用耦合交互策略建立磨削过程中工艺系统的多维交互模型，建立基于工艺系统多维交互作用磨削稳定性的定量化辨识模型，提出一套保障硬脆材料高效稳定磨削加工的磨削过程数字化建模、多维交互算法与工艺参数优化方法。项目研究成果对阐明磨削过程中工艺系统多维交互作用机理，揭示工艺系统多维交互作用下磨削稳定性的复杂响应机制具有重要意义，最终为硬脆材料零件的高效高质量磨削加工提供理论和技术支撑。

本项目以端面磨削硬脆材料为对象，探索硬脆材料磨削工艺系统稳定性的多维交互机理在硬脆材料磨削工艺过程模型中，提出了基于细粒度砂轮切除形貌、磨粒分布和端面工艺特性的旋转随机磨粒模型、单位磨粒数模型以及端面磨削速度变化模型，实现磨削力的精准预测；在工艺系统建模中，建立简化的磨削工艺系统模型，通过模态试验获取工艺系统的阻尼比与频响参数输入到工艺系统有限元模型并验证，进而建立了基于磨削力与磨削工艺参数交互耦合的多维交互模型，形成磨削稳定性的定量化辨识模型；基于VB6.0搭建耦合仿真软件接口，根据耦合仿真方法设定交互耦合收敛条件，迭代获得更精确的交互结果，为后续工艺设计和加工参数的合理选择奠定了理论基础。在模态测试基础上绘制磨削稳定性叶瓣图，获得稳定磨削区间，采用蚁群算法对磨削工艺参数进行优化，实现高效稳定磨削。本项目实施为硬脆材料零件的高精度和高效生产提供理论和技术支撑。