Model of an abrasive belt grinding surface removal contour and its application

Abstract

Belt grinding technology is used for machining the complex surface of a blade; however, it is difficult to ensure processing accuracy. To solve this problem, a surface removal contour (SRC) model for grinding the complex surface of a blade is proposed. First, this paper discusses why the normal contact pressure between the grinding wheel and workpiece surface accords with the Hertz contact theory, and further, the calculation method for the pressure distribution of the Hertz contact is given. Second, the SRC model is determined from the material removal rate (MRR) nonlinear model. To deter- mine the parameters of the MRR nonlinear and linear models, an abrasive belt grinding experiment was performed, which showed the relative error for the MRR nonlinear model was −1.1∼1.4 % and for the linear model was −12∼8 %. Third, combined with the Hertz contact theory, a SRC model based on the MRR nonlinear model was built. The SRC experiment showed the model's accumulative error was only ±1 %, but the accumulative error of the SRC model based on the MRR linearmodelwas −11∼5%.Finally,theapplicationofabrasive belt grinding on the blade showed the SRC model based on the MRR nonlinear model was better in dimensional precision and consistency of surface quality than the MRR nonlinear model. This led to more than 17.5 % surface roughness over the processing requirement and, beyond a 30 % maximum error, exceeded the standard. The residual stress on the blade surface after grinding appeared as a tensile stress.