Improved force prediction model for grinding Zerodur based on the comprehensive material removal mechanism

Sun Guoyan; Zhao Lingling; Zhao Qingliang; Gao Limin

摘要

There have been few investigations dealing with the force model on grinding brittle materials. However, the dynamic material removal mechanisms have not yet been sufficiently explicated through the grain-workpiece interaction statuses while considering the brittle material characteristics. This paper proposes an improved grinding force model for Zerodur, which contains ductile removal force, brittle removal force, and frictional force, corresponding to the ductile and brittle material removal phases, as well as the friction process, respectively. The critical uncut chip thickness alpha(gc) of brittle-ductile transition and the maximum uncut chip thickness alpha(gmax) of a single abrasive grain are calculated to identify the specified material removal mode, while the comparative result between alpha(gmax) and alpha(gc) can be applied to determine the selection of effective grinding force components. Subsequently, indentation fracture tests are carried out to acquire accurate material mechanical properties of Zerodur in establishing the brittle removal force model. Then, the experiments were conducted to derive the coefficients in the grinding force prediction model. Simulated through this model, correlations between the grinding force and grinding parameters can be predicted. Finally, three groups of grinding experiments are carried out to validate the mathematical grinding force model. The experimental results indicate that the improved model is capable of predicting the realistic grinding force accurately with the relative mean errors of 6.04% to the normal grinding force and 7.22% to the tangential grinding force, respectively. (C) 2018 Optical Society of America.

机译：在磨削脆性材料上处理力量模型几乎没有调查。然而，在考虑脆性材料特性的同时，尚未通过晶粒工件相互作用状态充分地阐述动态材料去除机制。本文提出了一种改进的Zerodur的研磨力模型，其含有延性去除力，脆性去除力和摩擦力，分别对应于延性和脆性材料去除相以及摩擦过程。计算脆性延展性转变的临界未切屑厚度α（GC）和单个磨粒的最大未接枝芯片厚度α（Gmax）以识别规定的材料去除模式，而α（Gmax）和α之间的比较结果（GC）可应用于确定有效磨削力组分的选择。随后，进行压痕断裂试验以在建立脆性去除力模型时获得Zerodur的精确材料力学性能。然后，进行实验以导出研磨力预测模型中的系数。通过该模型模拟，可以预测研磨力和研磨参数之间的相关性。最后，进行三组研磨实验以验证数学磨削力模型。实验结果表明，改进的模型能够以6.04％的相对平均误差为正常研磨力和切向研磨力的相对平均误差精确地预测现实的研磨力。（c）2018年光学学会。

Improved force prediction model for grinding Zerodur based on the comprehensive material removal mechanism

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