Abstract
Contact calculation is of great importance in predicting the material removal (MR) of flexible grinding process (FGP). The contact is mostly considered approximately constant in the existing MR models, while the situations that contact varies a lot after FGP are ignored. Therefore, a novel model is proposed in this paper to take those situations into consideration. Firstly, the nonconstant-contact situation is introduced. Then, an equivalent method is developed to convert the nonconstant-contact grinding process into the accumulation of several quasi-constant-contact grinding processes. Based on the equivalent method, a MR model is established, and the procedure to obtain the model parameters by the finite element analysis (FEA) is introduced. In the end, the equivalent method and the MR model are tested by a series experiments of different process parameters. Results show that the proposed MR model can predict the material removal effectively for the nonconstant-contact situations.
Highlights
Flexible grinding process (FGP) plays an important role in the finishing stage of many precision parts such as aero-engine blades, optical lenses and medical instruments, which can be used for the machining tolerance reduction, the surface integrity improvement and the local error correction of the parts [1]
Considering the error caused by tool wear and measurement, the results indicate within a quite large range of material removal (MR), the MR of the two grinding processes remains approximately equal independent of the shape of the tool and workpiece
In order to predict the material removal of flexible grinding process for the nonconstant-contact situations, a novel MR model is established in this paper
Summary
Flexible grinding process (FGP) plays an important role in the finishing stage of many precision parts such as aero-engine blades, optical lenses and medical instruments, which can be used for the machining tolerance reduction, the surface integrity improvement and the local error correction of the parts [1]. The geometric accuracy of parts is ensured by machining processes, and FGP is applied after machining processes to improve the surface integrity under the condition of not reducing the precision. To ensure the geometric accuracy of the parts, much effort has been made to predict the material removal (MR) in the automatic FGP. There are generally three kinds of prediction models, including experimental models, theoretical models and statistical models. Experimental models build the expressions through fitting the experimental data [3], mostly single-factor or orthogonal experiments. Investigations are conducted considering the size, shape and height distribution of the abrasives in the statistical models, and the deformation stages including elastic, elastic-plastic and plastic deformation are analyzed [7,8,9]. The hypothesis method is utilized as well for the prediction [10]
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