目的 探究工艺参数对纵扭超声ELID磨削GCr15钢表面粗糙度的影响,提高轴承套圈滚道磨削加工质量。方法 采用纵扭超声振动与ELID磨削相结合的方法,在理论分析纵扭超声ELID复合磨削对工件表面粗糙度影响的基础上,进行纵扭超声ELID复合切入式成形磨削GCr15轴承套圈滚道的试验研究。通过不同修整方式的砂轮磨削试验对比,探究施加超声振动对砂轮在线修整效果和工件磨削表面质量的影响。通过正交试验和单因素试验,从表面形貌的角度探究磨削工艺参数对工件表面粗糙度的影响。结果 不同修整方式的砂轮磨削试验结果表明,施加纵扭超声振动对砂轮在线电解修整效果和磨削表面质量均有提升作用。正交试验结果表明,加工参数在轴承套圈滚道纵扭超声ELID复合磨削中对工件表面粗糙度的影响主次为：径向进给速度>砂轮转速>占空比>工件转速>电解电压。单因素试验结果表明,与ELID磨削相比,纵扭超声ELID复合磨削可显著降低工件表面粗糙度,且工件表面粗糙度随超声振幅的增加而减小,随着磨粒粒度的增大而增大,随着砂轮转速、径向进给速度和占空比的增大而先减小后增大。在纵向超声振幅为2.4 μm、ELID电解电压为60 V、径向进给速度为2 μm/min、砂轮转速为6 000 r/min以及占空比为50%时,采用W10粒度的砂轮磨削后的工件表面粗糙度最低为0.081 μm,实现了工件表面的镜面磨削。结论 采用纵扭超声ELID复合磨削技术加工GCr15钢轴承滚道能够在提高砂轮在线电解修整效果的同时获得表面粗糙度更低的加工表面,实现镜面磨削效果,为实际工程应用及生产实践提供参考。
Abstract
GCr15 steel is widely used in the bearing manufacturing field due to its excellent properties. However, traditional plunge grinding faces issues such as unstable surface quality, rapid wheel wear, high grinding forces, and elevated temperatures, which leads to workpiece surface damage. Focusing on the impact of process parameters on the surface roughness of GCr15 steel during longitudinal-torsional ultrasonic ELID grinding, a method that combined longitudinal-torsional ultrasonic vibration with ELID grinding was employed. Based on the theoretical analysis of the impact of longitudinal-torsional ultrasonic ELID composite grinding on workpiece surface roughness, an experimental research on longitudinal-torsional ultrasonic ELID composite plunge form grinding of GCr15 bearing ring raceways was conducted. Through comparative grinding tests of wheels with different dressing methods, the effects of applying ultrasonic vibration on the online dressing performance of the wheel and the surface quality of the ground workpiece were investigated. An orthogonal experiment was designed and five process parameters were selected, including radial feed rate, wheel speed, duty cycle, workpiece speed, and electrolytic voltage, with surface roughness as the evaluation indicator, to explore the primary and secondary effects of these parameters on surface roughness. Additionally, a single-factor experiment was designed and five process parameters were selected including ultrasonic amplitude, wheel grain size, wheel radial feed rate, wheel speed, and ELID power supply duty cycle to investigate the effect of each parameter on surface roughness while keeping other parameters constant. The results indicated that, compared to conventional dressing and ELID dressing, the application of longitudinal-torsional ultrasonic vibration could simultaneously enhance the online electrolytic dressing performance of the grinding wheel and the surface quality of the machined workpiece. This verified the theoretical analysis that applying longitudinal-torsional ultrasonic vibration would result in a denser and more uniform oxide film being formed on the grinding wheel through electrolysis, and would strengthen the mechanical grinding action, thereby further improving the machining quality of the workpiece during grinding. The range analysis of the orthogonal experiment revealed that the primary and secondary effects of the process parameters on surface roughness were as follows: radial feed rate > wheel speed > duty cycle > workpiece speed > electrolytic voltage. The single-factor experiment results showed that, compared to ELID grinding, longitudinal-torsional ultrasonic ELID composite grinding significantly reduced workpiece surface roughness. Moreover, the workpiece surface roughness decreased with an increase in ultrasonic amplitude, increased with an increase in grain size, and initially decreased and then increased with an increase in wheel speed, radial feed rate, and duty cycle. When the longitudinal ultrasonic amplitude was 2.4 μm, the ELID electrolytic voltage was 60 V, the radial feed rate was 2 μm/min, the wheel speed was 6 000 r/min, and the duty cycle was 50%, the surface roughness of the workpiece ground with a W10 grain size wheel was as low as 0.081 μm, achieving mirror-like grinding of the workpiece surface. Therefore, employing longitudinal-torsional ultrasonic ELID composite grinding technology for machining GCr15 steel bearing raceways can improve the online electrolytic dressing performance of the wheel while obtaining a processed surface with lower surface roughness, achieving a mirror-like grinding effect, and providing valuable references for practical engineering applications and production practices.
关键词
纵扭超声振动 /
ELID磨削 /
极差分析 /
单因素试验 /
表面粗糙度 /
镜面磨削
Key words
longitudinal-torsional ultrasonic grinding /
ELID grinding /
range analysis /
single-factor experiment /
surface roughness /
mirror-like grinding
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基金
国家自然科学基金项目（52175399）; 河南省重点研发与推广专项（242102221032）
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