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.
Key words
longitudinal-torsional ultrasonic grinding /
ELID grinding /
range analysis /
single-factor experiment /
surface roughness /
mirror-like grinding
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Funding
National Natural Science Foundation of China (52175399); Key R&D and Promotion Program of Henan Province (242102221032)
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