Electroplated diamond grinding wheels are characterized by high hardness, but they have poor chip tolerance, which generates significant grinding forces. They require extended grinding times, and suffer from issues such as burns and abrasive loss. In order to meet the needs of efficient and precise grinding and fully utilize the excellent grinding performance of structured grinding wheels, this study employs a bionic design concept for the blade sequence and conducted innovative design and preparation of structured electroplated diamond grinding wheels. The study also investigates the ablation of electroplated diamond wheels using nanosecond pulsed lasers, and reveals the effects of laser parameters on the ablation process. Main laser parameters that affect the laser ablation energy and the surface quality of the grinding wheel after ablation are the laser spot overlap rate, the laser line overlap rate, the laser power, and the laser scanning speed. As the number of laser scans increases, the laser focus shifts downward. Therefore, adjustments in scanning speed and focusing distance are necessary. Specifically, for every 100 additional scans, the focusing distance should be adjusted by 100 µm. A series of experimental studies show that the optimal laser parameters for ablation machining of electroplated diamond wheels are a spot overlap rate of 40%, a line overlap rate of 80%, a power of 20 W, and a feed processing scanning times of 500 times. Based on these findings, electroplated diamond wheels with bionic blade sequence structures are successfully fabricated. Then, with titanium-aluminum alloy specimens as grinding objects, and the grinding characteristics of electroplated diamond wheels with blade sequence bionic structures are deeply investigated in terms of grinding force, grinding surface quality, and grinding wheel wear characteristics. The results show that the grinding performance of bionic structured wheels with blade sequences is better than that of ordinary wheels. Compared with ordinary grinding wheels, under varying processing parameters, the normal grinding force of blade sequence bionic structured grinding wheels is reduced by 11%-51.25%, and the tangential grinding force is reduced by 9.15%-29.88%. As the blade sequence coefficient increases, the grinding force reduction effect becomes gentler. Compared with ordinary grinding wheels, under varying processing parameters, the workpiece surface roughness after grinding with blade sequence bionic structured grinding wheels is reduced by 30.13%-65.28%. However, as the blade sequence coefficient increases, the workpiece surface roughness increases. Therefore, the blade sequence coefficient should not be too large. Compared with ordinary grinding wheels, the thickness of the workpiece deformation layer after grinding with bionic structured grinding wheels is greater than that of ordinary grinding wheels, and it increases with the increase of the blade sequence coefficient. Compared with ordinary grinding wheels, the wear degree of blade sequence bionic structured grinding wheels is smaller and their life is longer. However, a too large blade sequence coefficient will reduce the abrasive density and increase the wear degree of the grinding wheel. Therefore, when designing bionic structured electroplated diamond wheels with blade sequence arrangements, the blade sequence coefficient should not be too large.
Key words
structured grinding wheel /
grinding /
blade sequence bionics /
grinding characteristics /
blade sequence coefficient
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Funding
Project of Liaoning Provincial Department of Education (LJ212410143043, LJ222410143059, LJ232410143042); Foundation of Key Laboratory of Rapid Development & Manufacturing Technology for Aircraft (Shenyang Aerospace University) (JYBSYS202409); Natural Science Foundation of Liaoning Provincial (2021-MS-263)
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