Modeling of material removal depth in robot abrasive belt grinding based on energy conversion

Abstract

Accurate material removal is of great significance to ensure the machining accuracy of robot abrasive belt grinding (RABG). In this paper, a material removal depth (MRD) model for RABG of superalloy is proposed based on the energy conversion in grinding. Based on the characteristics of the shape and protrusion height distribution of grits, the energy conversion equation is established through the force analysis of the interference between grits and workpiece, and then the expression of material removal depth is derived by combining the Hertz elastic contact theory. In addition, in view of the change of belt coverage ratio caused by the structured belt wear, the expression of grit distribution density considering belt wear is obtained through the Archard wear model and applied to the MRD model. The MRD model is evaluated by the experiment, and the results show that the proposed model has good prediction ability. Furthermore, the effects of grinding parameters on MRD are analyzed, and the grinding parameters that take into account both the MRD and surface quality are discussed. This research provides a theoretical reference for material removal research in RABG.