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Volume 45 Issue 1
Mar.  2025
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Article Navigation >  Diamond & Abrasives Engineering  > 2025  >  45(1): 93-101
ZHANG Rui, ZHOU Shuaikang, ZHAO Huadong, ZHU Zhenwei, HE Honghui, LIU Chang. Force of dressing grinding wheels by diamond rollers with orderly arrangement grains[J]. Diamond & Abrasives Engineering, 2025, 45(1): 93-101. doi: 10.13394/j.cnki.jgszz.2024.0004
Citation: ZHANG Rui, ZHOU Shuaikang, ZHAO Huadong, ZHU Zhenwei, HE Honghui, LIU Chang. Force of dressing grinding wheels by diamond rollers with orderly arrangement grains[J]. Diamond & Abrasives Engineering, 2025, 45(1): 93-101. doi: 10.13394/j.cnki.jgszz.2024.0004
shu

Force of dressing grinding wheels by diamond rollers with orderly arrangement grains

doi: 10.13394/j.cnki.jgszz.2024.0004

  • School of Mechanical and Power Engineering, Zhengzhou University, Zhengzhou 450001, China

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  • Received Date: 2024-01-04
  • Accepted Date: 2024-04-18
  • Rev Recd Date: 2024-04-01
    • Available Online: 2024-04-18
    Abstract
  •   Objectives  With the increasing improvement of science and technology and industrial levels, the modern manufacturing industry has higher and higher precision requirements for grinding processing, and the grinding quality can be improved by enhancing the ability of diamond dressing rollers. However, the current research on the grinding dressing process is mostly based on experiments. Since grinding is a high-speed and complex machining process, the dressing experimental cost of diamond rollers is higher. Therefore, this paper explores the influence of surface diamond grain arrangement on the dressing ability of diamond rollers through finite element simulation, and designs experiments to verify the reliability of the simulation results.   Methods  The finite element analysis software Abaqus is used to carry out kinematic simulation of the dressing grinding process of the roller. First of all, in order to simulate the randomness of the real abrasive grain shape, the sphere method of plane-cutting cubes is used to obtain a more realistic abrasive grain model. Algorithms are designed for the coordinates of abrasive grains in three types of arrangement: array, misalignment, and leaf sequence, to achieve the accurate arrangement of abrasive grains on the surface of the roller model. The Johnson-Holmquist-2 (JH-2) intrinsic parameters model of 99.5% alumina ceramics is used to approximately characterize the damage evolution of white corundum grinding wheels during dressing. To verify the accuracy of the results obtained through this simulation method, dressing experiments are set up to form a control with the simulation group.   Results  Taking the dressing force generated in the dressing process as the evaluation index, the simulation and experimental results are analyzed: (1) A comparative analysis of the data obtained from the simulation is carried out, and it is found that diamond wheels with surface abrasive grains arranged in an array manner would generate a larger dressing force during the dressing process, followed by the staggered-arrangement wheels, and the diamond wheels with a leaf-sequence arrangement would have the smallest dressing force. In other words, the arrangement of abrasive grains on the surface of the diamond dressing wheel affects the dressing force. (2) The dressing force results obtained from the experiments also show that under these three arrangements, the dressing force generated by the array roller is the largest, and the dressing force generated by the leaf sequence is the smallest. (3) Comparing the dressing force data obtained from the simulation and experiment, it can be seen that the fluctuation of the dressing force obtained from the experiment is smaller than that of the simulation. The maximum error of both normal dressing force is 12.87%, and the maximum error of tangential dressing force is 17.16%.   Conclusions  (1) Comparing the dressing force results of the simulation and experiment, it is found that the fluctuation of the experimental data is smaller than that of the simulation results. This is due to the fact that the abrasive grains in the simulation are generated randomly. Even if two neighboring abrasive grains differ in parameters such as protruding height, effective action area, and the angle of abrasive grains' vertices, the fluctuation of the dressing force is still larger under the state of smooth grinding. The diamond rollers used in the experiments have undergone surface reshaping treatment, and the parameters such as the emergence height and vertex angle of the abrasive grains on the surface are more consistent with the simulation model. As a result, the fluctuation of the dressing force is smaller and smoother. The dressing force measured in the experiment is smaller compared with the simulation, which indicates that the dressing roller can be shaped to make the dressing process smoother and improve its dressing ability. (2) The reason for the difference in dressing force of diamond wheels with different arrangements of abrasive grains: Under the condition of the same concentration of abrasive grains on the surface, the abrasive grains of the roller with an array arrangement result in fewer effective abrasive grains due to a large number of overlapping grinding trajectories. In contrast, the leaf-sequence arrangement has the unique characteristic where each abrasive grain is located on a circumference that is different from that of any other abrasive grain. Therefore, the trajectory lines of each abrasive grain on it do not overlap, resulting in the largest number of effective abrasive grains and the smallest dressing force. (3) The similarity between the simulation and the dressing force obtained from the experiment verifies the reliability of the simulation of the dressing process of the wheel by finite element analysis. It also proves the feasibility of replacing the material properties of the white corundum grinding wheel with the JH-2 intrinsic parameter of alumina ceramics with 99.5% content in the kinetic simulation.

     

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