Effect of dressing with form grinding wheel on grinding surface integrity of 18CrNiMo7-6 steel
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摘要: 为了探究修整切深ad、轴向进给速度fd和修整速比qd等修整工艺参数对18CrNiMo7-6齿轮钢磨削表面完整性的影响，分别采用树脂结合剂金刚石碟轮、青铜结合剂金刚石碟轮和单颗粒金刚石笔3种修整工具对陶瓷结合剂铬刚玉砂轮进行成形修整工艺正交试验，并用修整后的铬刚玉砂轮对18CrNiMo7-6齿轮钢进行横磨试验。结果表明：随着各修整工艺参数的增大，齿轮钢磨削加工表面粗糙度Ra增大，磨削表面更容易产生残余压应力；通过归一化无量纲方法综合评价3种修整工具的磨削表面完整性，表明采用青铜结合剂金刚石碟轮修整时的磨削表面完整性优于其余2种修整工具的，且当ad=4 μm，fd=100 mm/min，qd=0.3时齿轮钢，磨削表面的完整性较优。
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关键词:
- 成形砂轮修整 /
- 金刚石碟轮 /
- 表面完整性 /
- 18CrNiMo7-6齿轮钢 /
- 正交试验
Abstract: In order to explore the influence of dressing process parameters, such as dressing depth ad, axial feed speed fd and dressing speed ratio qd, on the grinding surface integrity of 18CrNiMo7-6 gear steel, orthogonal experiments were conducted for shaping dressing process using ceramic bonded chrome corundum grinding wheels with resin bonded diamond disc wheels, bronze bonded diamond disc wheels and single particle diamond pens, respectively. The cross grinding test of 18CrNiMo7-6 gear steel was carried out with a chrome corundum wheel after dressing. The results show that the surface roughness Ra of the grinding process increased with the increase of the dressing process parameters, and residual compressive stresses were more easily obtained on the grinding surface. The comprehensive evaluation of the grinding surface integrity for the three dressing tools, using a normalized dimensionless method, shows that the grinding surface integrity of the bronze-bonded diamond disc wheel dressing is better than the other two dressing methods. Furthermore, the grinding surface integrity is better when ad=4 μm, fd=100 mm/min, and qd=0.3. -
图 3 树脂结合剂金刚石碟轮、青铜结合剂金刚石碟轮和单颗粒金刚石笔
Figure 3. Resin bonded diamond disc wheel, bronze bonded diamond disc wheel and single particle diamond pen
图 4 树脂金刚石碟轮数控成形修整铬刚玉砂轮
Figure 4. Resin bonded diamond disc wheel CNC forming and dressing chrome corundum grinding wheel
图 6 不同修整工具下修整切深对表面完整性的影响
Figure 6. Effect of trimming depth of cut on surface integrity with different trimming tools
图 7 不同修整工具下轴向进给速度对表面完整性的影响
Figure 7. Effect of axial feed rate on surface integrity with different dressing tools
图 8 不同修整工具下，修整速比对表面完整性的影响
Figure 8. Effect of dressing speed ratio on surface integrity with different dressing tools
表 1 砂轮线速度及修整速比试验参数
Table 1. Test parameters of grinding wheel linear speed and dressing speed ratio
修整轮线
速度 vr / (m·s−1)陶瓷结合剂铬刚玉
砂轮线速度 vs / (m·s−1)修整速比 qd 10.5 35 0.3 21.0 35 0.6 31.5 35 0.9 
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表 2 修整正交试验参数
Table 2. Trimming orthogonal test parameters
水平 X1 X2 X3 修整切深 ad / μm 轴向进给
速度 fd / (mm·min−1）修整速比 qd 1 4 100 0.3 2 7 200 0.6 3 10 300 0.9
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表 3 横磨工艺参数设定
Table 3. Horizontal grinding process parameter setting
工艺参数 参数值 砂轮线速度 vs / （m·s−1） 35 工件转速 n / （r·min−1） 200 砂轮径向进给速度 vf / （mm·min−1） 0.2 磨削总量 d / μm 60 无进给光磨时间 t / s 3
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表 4 金刚石碟轮修整后磨削表面完整性无量纲综合量值
Table 4. Dimensionless comprehensive value of grinding surface integrity of diamond disc wheel after dressing
试验编号 修整切深 ad / μm 轴向进给速度 fd / (mm·min−1） 修整速比 qd 综合量值（树脂） X树脂 综合量值（青铜） X青铜 1 4 100 0.3 0.462 828 0.706 182 2 4 200 0.6 0.490 994 0.629 858 3 4 300 0.9 0.671 446 0.619 218 4 7 100 0.6 0.467 726 0.651 310 5 7 200 0.9 0.680 168 0.569 448 6 7 300 0.3 0.529 538 0.641 498 7 10 100 0.9 0.668 686 0.637 474 8 10 200 0.3 0.500 632 0.692 488 9 10 300 0.6 0.565 014 0.575 290 综合量值平均值 0.559 670 0.635 863
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表 5 单颗粒金刚石笔修整后磨削表面完整性无量纲综合量值
Table 5. Dimensionless comprehensive value of ground surface integrity after dressing with single particle diamond pen
试验编号 修整切深 ad / μm 轴向进给速度 fd / (mm·min−1） 综合量值 X笔 1 4 100 0.399 970 2 4 200 0.532 630 3 4 300 0.550 908 4 7 100 0.495 294 5 7 200 0.530 964 6 7 300 0.546 728 7 10 100 0.562 916 8 10 200 0.590 518 9 10 300 0.609 462 综合量值平均值 0.535 488
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