Numerical calculation of grinding wheel wear for spiral groove grinding

Xianli Liu,Steven Y Liang,Zhan Chen,Shipeng Wang,Jiaqi Zhou,Caixu Yue,Mengdi Xu

doi:10.1007/s00170-021-08617-8

Abstract

Due to its good cutting performance in titanium alloy machining, integral end mills are more and more used in machining aero-engine impeller blades. The tool spiral groove plays the role of chip acceptor and chip removal, and the accuracy of its parameters has an important effect on the cutting performance. In the grinding process of the spiral groove, the grinding wheel’s external grinding is mainly involved in the grinding task. The grinding wheel’s wear degree is related to the grinding time and grinding times of the grinding wheel, and the wear of the grinding wheel will lead to the change of the parameters of the spiral groove. To achieve the accurate solution of the grinding wheel surface wear profile, image processing technology was used to extract the spiral groove end section contour coordinates of the grinding wheel and fit them. The worn sand profile was solved based on the contact line principle, and the grinding wheel wear amount was obtained. The traditional reconstruction method was used to verify the algorithm. The results show that the accuracy of the reverse algorithm for the wear profile of the grinding wheel is relatively high.

Highlights

Grinding wheel wear will cause a series of grinding defects such as grinding burns, surface vibration pattern, and crack, and affect the tool spiral groove[2]
Wu et al.[6] proposed a grinding wheel wear measurement and machining error compensation system based on acoustic emission detection technology
This paper uses image processing technology to detect the edge section profile of the spiral groove of the solid end mill grinded by the worn grinding wheel, extract the edge and fit the edge point of the spiral groove end section into an equation, based on the principle of the contact line, in the grinding wheel position Under the premise that the profile and spiral groove shape are known, the worn sand profile is solved, which provides a theoretical basis for analyzing the influence of grinding wheel wear on the spiral groove parameters

Summary

Introduction

Modern automated machining equipment uses higher cutting speeds in order to achieve high efficiency and low-cost machining[1]. Wu et al.[6] proposed a grinding wheel wear measurement and machining error compensation system based on acoustic emission detection technology. This paper uses image processing technology to detect the edge section profile of the spiral groove of the solid end mill grinded by the worn grinding wheel, extract the edge and fit the edge point of the spiral groove end section into an equation, based on the principle of the contact line, in the grinding wheel position Under the premise that the profile and spiral groove shape are known, the worn sand profile is solved, which provides a theoretical basis for analyzing the influence of grinding wheel wear on the spiral groove parameters (rake angle, core diameter, blade width)

Principle of contact line

Numerical solution of rotation angle vp

Image edge detection

Experimental verification

Conclusions