Abstract
K9 optical glass has superb material properties used for various industrial applications. However, the high hardness and low fracture toughness greatly fluctuate the cutting force generated during the grinding process, which are the main factors affecting machining accuracy and surface integrity. With a view to further understand the grinding mechanism of K9 glass and improve the machining quality, a new arithmetical force model and parameter optimization for grinding the K9 glass are introduced in this study. Originally, the grinding force components and the grinding path were analyzed according to the critical depth of plowing, rubbing, and brittle tear. Thereafter, the arithmetical model of grinding force was established based on the geometrical model of a single abrasive grain, taking into account the random distribution of grinding grains, and this fact was considered when establishing the number of active grains participating in cutting Nd-Tot. It should be noted that the tool diameter changed with machining, therefore this change was taking into account when building the arithmetical force model during processing as well as the variable value of the maximum chip thickness amax accordingly. Besides, the force analysis recommends how to control the processing parameters to achieve high surface and subsurface quality. Finally, the force model was evaluated by comparing theoretical results with experimental ones. The experimental values of surface grinding forces are in good conformity with the predicted results with changes in the grinding parameters, which proves that the mathematical model is reliable.
Highlights
Optical glass materials like BK7 or K9 are broadly applied in the production area of various optical accessories for use in visual products or engineering appliances, such as mirrors, prisms, lenses, automobile, aerospace, and panes due to its superior scratch impedance and light transmission properties [1,2,3]
The most important factor is grinding force, research on establishing and controlling the grinding force of hard and brittle materials (HBM) is important for machining HBM to enhance the grinding efficiency and to upgrade the grinding tool performance [10,11,12,13]
Previous studies lacked adequately representative the precise force model of the grinding process for HBM, several important reasons that are the instantaneous variation of grinding space and time as well as the mechanisms of material removal
Summary
Optical glass materials like BK7 or K9 are broadly applied in the production area of various optical accessories for use in visual products or engineering appliances, such as mirrors, prisms, lenses, automobile, aerospace, and panes due to its superior scratch impedance and light transmission properties [1,2,3]. Sun et al [16] proposed an arithmetical model of the grinding force for Zerodur glass in both brittle and ductile regions, considering the material removal mechanism and the influence of the frictional force. This model repealed the fact that not all grits are active during grinding, where the grits are randomly distributed on the wheel with their specific height and width, some of them are active and others have a free ride on the wheel. Previous studies lacked adequately representative the precise force model of the grinding process for HBM, several important reasons that are the instantaneous variation of grinding space and time as well as the mechanisms of material removal.
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