Abstract
(1) The alloy material 20CrMnTiH is widely used in gear manufacturing, but difficult to process, and its quantity (efficiency) and quality (surface quality) are generally negative correlation indicators. As a difficult but realistic problem, it is of important practical significance to explore how to efficiently grind high-precision low-carbon alloy gear workpieces. (2) Firstly, the pixel method was applied to analyze the grinding principles and explore the grinding parameters—the grinding wheel speed and grinding wheel frame moving speed—as well as the feed rate, which impacts the grinding indicators. Secondly, based on the ceramic microcrystalline corundum grinding wheel and the 20CrMnTiH gear workpiece, controlled experiments with 28 groups of grinding parameters were conducted. Moreover, the impact curves of the grinding parameters on the grinding indicators—the grinding efficiency, grinding wheel life, and surface roughness—were obtained by the multiple linear regression method. Finally, the multi-objective optimization method was used to comprehensively optimize the grinding process. (3) Compared with the traditional grinding process, under optimized grinding parameters, the 20CrMnTiH gear workpieces have a lower surface roughness and a longer grinding wheel life, and require a shorter time to achieve grinding accuracy. (4) The grinding experiments showed that the grinding parameters are linearly related to the grinding indicators. The optimization results show that the precision, efficiency, and economy of the 20CrMnTiH gear grinding process have been improved via the comprehensive optimization of the grinding parameters.
Highlights
As the second high-hardness material in nature, the microcrystalline corundum has dense texture and sharp-pointed particles, which has a significant and decisive impact on the material’s properties [1].Ceramics and resins are generally used as its binders for grinding, polishing, sand blasting, and precision casting
The optimization results show that the precision, efficiency, and economy of the 20CrMnTiH gear grinding process have been improved via the comprehensive optimization of the grinding parameters
The optimized grinding parameters and indicators are compared with the traditional indicators
Summary
As the second high-hardness material in nature, the microcrystalline corundum has dense texture and sharp-pointed particles, which has a significant and decisive impact on the material’s properties [1].Ceramics and resins are generally used as its binders for grinding, polishing, sand blasting, and precision casting. As the second high-hardness material in nature, the microcrystalline corundum has dense texture and sharp-pointed particles, which has a significant and decisive impact on the material’s properties [1]. The ceramic microcrystalline corundum is more and more applied as the material of the grinding wheel to grind the 20CrMnTiH gear workpiece. The selection of binder and composite abrasive is extraordinarily important, as the abrasive composition has a large influence on the physical properties of the grinding wheel [2,3]. The ceramic microcrystalline corundum grinding wheel prepared by hollow ball corundum particles as a pore former [7] has good microstructure and heat dissipation [8]. A large number of experiments have shown that because of the excellent hardness and heat dissipation characteristics, microcrystalline
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