| LIU Kaihua,XU Hanwei,GUAN Chaoliang,SUN Zizhou.Optimization of Time-controlled Grinding Removal Function for High-precision Spindle Mandrel[J],54(8):180-190 |
| Optimization of Time-controlled Grinding Removal Function for High-precision Spindle Mandrel |
| Received:July 26, 2024 Revised:January 26, 2025 |
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| DOI：10.16490/j.cnki.issn.1001-3660.2025.08.016 |
| KeyWord:time-controlled grinding spindle mandrel removal function optimization deterministic figuring cylindricity error roundness error |
| Author | Institution |
| LIU Kaihua |
College of Intelligence Science and Technology, National University of Defense Technology, Changsha , China;Hunan Key Laboratory of Ultra-precision Machining Technology, Changsha , China;National Key Laboratory of Equipment State Sensing and Smart Support, Changsha , China |
| XU Hanwei |
College of Intelligence Science and Technology, National University of Defense Technology, Changsha , China;Hunan Key Laboratory of Ultra-precision Machining Technology, Changsha , China;National Key Laboratory of Equipment State Sensing and Smart Support, Changsha , China |
| GUAN Chaoliang |
College of Intelligence Science and Technology, National University of Defense Technology, Changsha , China;Hunan Key Laboratory of Ultra-precision Machining Technology, Changsha , China;National Key Laboratory of Equipment State Sensing and Smart Support, Changsha , China |
| SUN Zizhou |
College of Intelligence Science and Technology, National University of Defense Technology, Changsha , China;Hunan Key Laboratory of Ultra-precision Machining Technology, Changsha , China;National Key Laboratory of Equipment State Sensing and Smart Support, Changsha , China |
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| Abstract: |
| The time-controlled grinding technology achieves deterministic figuring by precisely controlling the residence time of the grinding tool at different positions on the workpiece surface. This technology overcomes the limitations of the "precision copying" principle inherent in traditional machine tools, significantly enhancing the machining accuracy of mandrels. However, during the iterative machining process of time-controlled grinding, the single-pass accuracy convergence ratio exhibits a notable decreasing trend, eventually approaching a limit value. To address this issue, this study focuses on optimizing the removal function to further improve the machining accuracy of mandrels. Firstly, based on the principles of time-controlled grinding for mandrels, the morphological characteristics of existing removal functions are analyzed. A total of 1 596 removal function models with varying shapes and sizes are constructed and used to simulate the machining of mandrels with identical initial surface errors. Based on the simulation results, the influence of the shape and size of the removal function on machining accuracy are analyzed, leading to the proposal of a novel method to optimize the time-controlled grinding removal function by reducing its axial length, thereby enhancing the machining accuracy of mandrels. Secondly, key factors affecting the axial length of the removal function are identified through analyzing the time-controlled grinding device, and the time-controlled grinding device is improved by reducing the width of the contact wheel. Based on this, four contact wheels with widths values of 8, 12, 16, and 20 mm are fabricated, and four experimental models of time-controlled grinding removal functions with varying axial lengths are established. The error correction capabilities of these removal functions are analyzed using the normalized Fourier spectrum method. The results indicate that the removal function with the smallest axial length exhibits the best error correction capability. Finally, comparative machining experiments are conducted on four regions of the No.Ⅰmandrel, which nearly reaches its accuracy limit under existing conditions, using the four removal functions. Additionally, the removal function with the best machining performance is selected to perform reshaping experiments on the No.Ⅱmandrel to validate the effectiveness of the optimized removal function. The experimental results show that as the axial length of the removal function decreases, the machining accuracy of the four regions of the No.Ⅰmandrel follows a pattern of rapid initial improvement followed by gradual enhancement, consistent with the simulation results. Specifically, the average roundness error in the machining area of the removal function with the smallest axial length decreases from 0.209 μm to 0.148 μm (convergence ratio:1.41), and the cylindricity error decreases from 0.464 μm to 0.396 μm (convergence ratio:1.17), representing a significant improvement over pre-optimization levels. For the No.Ⅱmandrel, its average roundness error decreases from 0.182 μm to 0.102 μm (convergence ratio:1.78), and its cylindricity error decreases from 0.566 μm to 0.370 μm (convergence ratio:1.53), further demonstrating the effectiveness of the optimized removal function. The research findings demonstrate that optimizing the time-controlled grinding removal function by reducing its axial length can significantly enhance the iterative machining accuracy of mandrels, providing a new theoretical and technical support for machining of high-precision mandrels. |
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