Research on abrasive wear dress of CBN honing tool based on single abrasive cutting
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摘要: 采用单颗磨粒试验方法，以4Cr13不锈钢为修整材料，研究大长径比CBN铰珩工具修整过程中的磨粒磨损特性。试验结果显示：与普通切削相比，超声切削时的平均切削力降低60%～80%，但磨粒在短时间内大块破碎，磨削比严重下降。超声切削时的磨粒−工件接触比在0.6～0.8，磨粒主要处于断续切削过程，其最大切削宽度比普通切削时的增加2.7倍，且磨粒受到的最大瞬时切削力增加。根据点云信息对磨粒进行逆向建模，并对建立的单颗磨粒切削仿真模型的瞬时切削力进行定量分析。仿真结果显示：超声切削时的最大切向力比普通切削时的增加20%以上，且力的波动幅度超过80%。Abstract: The abrasive wear characteristics of large length to diameter ratio CBN single-pass honing tools during ultrasonic dressing process were studied by single abrasive test with 4Cr13 stainless steel as dressing material. The test results show that the average cutting force during ultrasonic cutting is reduced by 60%～80% compared to that during ordinary cutting. However, the abrasives break in a short time and the grinding ratio is seriously reduced. The abrasive-workpiece contact ratio during ultrasonic cutting is mainly between 0.6 and 0.8, and the abrasives are mainly in the intermittent cutting process. Moreover, the maximum cutting width during ultrasonic cutting increase by 2.7 times compared with that during ordinary cutting, leading to an increase in the maximum cutting force on the abrasives. According to the point cloud information, the abrasive was modeled inversely, and a single abrasive cutting simulation model was established to quantitatively analyze the maximum cutting force. The simulation results show that, compared with that during ordinary cutting, the maximum cutting force during ultrasonic cutting is more than 20% higher, and the fluctuation of cutting force is more than 80%.
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Key words:
- single abrasive cutting /
- abrasive wear /
- ultrasonic /
- cutting force.
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图 4 CBN磨粒形貌演变（普通切削）
Figure 4. Evolution of CBN abrasive grain morphology (ordinary cutting)
图 5 CBN磨粒形貌演变（超声切削）
Figure 5. Evolution of CBN abrasive grain morphology (ultrasonic cutting)
图 9 普通切削和超声切削时的切削宽度
Figure 9. Cutting width during normal cutting and ultrasonic cutting
图 11 超声切削时的磨粒轨迹与切削区分布
Figure 11. Abrasive particle trajectory and cutting zone distribution during ultrasonic cutting
表 1 试验参数
Table 1. Test parameters
参数 取值 CBN磨粒基本颗粒尺寸 D / μm 400～425 主轴转速 n / (r·min−1) 2 000 轴向进给速度 va / (mm·min−1) 6 切削深度 ap / μm 2 超声振幅 A / μm 4 超声频率 f / kHz 21.5 
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表 2 材料物理性质
Table 2. Material physical properties
材料 密度 ρ / (kg·m−3) 弹性模量 E / GPa 泊松比 υ CBN 3 480 710 0.20 4Cr13 7 800 200 0.24
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表 3 4Cr13的Johnson-Cook模型参数
Table 3. Johnson-Cook model parameters of 4Cr13
参数 取值 屈服应力参数 A1 / MPa 600 硬化系数 B / MPa 221 应变率系数 C 0.023 硬化指数 n1 0.6 温度系数 m 1
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