Study on a probabilistic algorithm for the forming and 3D characterization of special-shaped surfaces under profile grinding

doi:10.1007/s40436-023-00467-9

Advances in Manufacturing ›› 2024, Vol. 12 ›› Issue (2): 288-299.doi: 10.1007/s40436-023-00467-9

• • 上一篇

Study on a probabilistic algorithm for the forming and 3D characterization of special-shaped surfaces under profile grinding

Zhao-Qing Zhang^1,2,3, Kai-Ning Shi^1,2,3, Yao-Yao Shi^1,2,3, Yi-Hui Song^1,2,3, Zhe He^1,2,3, Ya-Song Pu^1,2,3

1 School of Mechanical Engineering, Northwestern Polytechnical University, Xi'an 710072, People's Republic of China;
2 Key Laboratory of High Performance Manufacturing for Aero Engine (Northwestern Polytechnical University), Ministry of Industry and Information Technology, Xi'an 710072, People's Republic of China;
3 Engineering Research Center of Advanced Manufacturing Technology for Aero Engine (Northwestern Polytechnical University), Ministry of Education, Xi'an 710072, People's Republic of China

收稿日期:2022-12-01 修回日期:2023-04-27 发布日期:2024-05-16
通讯作者: Kai-Ning Shi,E-mail:shikaining@nwpu.edu.cn E-mail:shikaining@nwpu.edu.cn
作者简介:Zhao-Qing Zhang is currently a Ph. D. candidate of Mechatronic Engineering at Northwestern Polytechnical University, Xi'an, China. His main research interests include grinding surface integrity of difficultto-cut materials and ultrasonic assisted grinding technology of hard and brittle materials;
Kai-Ning Shi is currently an Associate Professor of Mechanical Engineering at Northwestern Polytechnical University, Xi'an, China. His main research interests include energy efficiency analysis in manufacturing, tool condition monitoring, the cutting mechanism of difficult-to-cut materials, and surface integrity;
Yao-Yao Shi is a Professor of Mechanical Engineering at Northwestern Polytechnical University, Xi'an, China. His research interests include electromechanical control, special numerical control machine tools, high-efficiency NC machining, and adaptive finishing technology;
Yi-Hui Song is currently a Ph.D. candidate of Mechatronic Engineering at Northwestern Polytechnical University, Xi'an, China. His research interest is grinding surface integrity of difficult-to-cut materials;
Zhe He is currently a Ph.D. candidate of Mechatronic Engineering at Northwestern Polytechnical University, Xi'an, China. His research interest is grinding surface integrity of difficult-to-cut materials;
Ya-Song Pu is currently a Ph.D. candidate of Mechatronic Engineering at Northwestern Polytechnical University, Xi'an, China. His research interests include industrial robot polishing and advanced CAD/CAM.
基金资助:
Acknowledgments This research was sponsored by the National Natural Science Foundation of China(Grant No.51905442) and the National Major Science and Technology Projects of China(Grant No.2017-VII-0002-0095).

Study on a probabilistic algorithm for the forming and 3D characterization of special-shaped surfaces under profile grinding

Zhao-Qing Zhang^1,2,3, Kai-Ning Shi^1,2,3, Yao-Yao Shi^1,2,3, Yi-Hui Song^1,2,3, Zhe He^1,2,3, Ya-Song Pu^1,2,3

1 School of Mechanical Engineering, Northwestern Polytechnical University, Xi'an 710072, People's Republic of China;
2 Key Laboratory of High Performance Manufacturing for Aero Engine (Northwestern Polytechnical University), Ministry of Industry and Information Technology, Xi'an 710072, People's Republic of China;
3 Engineering Research Center of Advanced Manufacturing Technology for Aero Engine (Northwestern Polytechnical University), Ministry of Education, Xi'an 710072, People's Republic of China

Received:2022-12-01 Revised:2023-04-27 Published:2024-05-16
Contact: Kai-Ning Shi,E-mail:shikaining@nwpu.edu.cn E-mail:shikaining@nwpu.edu.cn
Supported by:
Acknowledgments This research was sponsored by the National Natural Science Foundation of China(Grant No.51905442) and the National Major Science and Technology Projects of China(Grant No.2017-VII-0002-0095).

摘要/Abstract

摘要： Abstract Profile grinding is the most crucial method for the ultra-precision machining of special-shaped surfaces. However, profile grinding produces a unique machining profile, and many random factors in the machining process lead to complex surface characteristics. In this study, the structural and probabilistic characteristics of the profile grinding of a special-shaped surface were analyzed, and a probabilistic algorithm for the forming and 3D characterization of special-shaped surfaces under profile grinding was developed. The forming process of a GH738 blade tenon tooth surface was considered as an example to demonstrate the algorithm. The comparison results showed that the simulation results had similar surface characteristics to the measurement results, and the relative error range of the 3D roughness parameter was 0.21 %-19.76 %, indicating an accurate prediction and characterization of the complex special-shaped surface under the action of multiple factors.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00467-9

关键词: Special-shaped surface, Profile grinding, Surface morphology, 3D characterization

Abstract: Abstract Profile grinding is the most crucial method for the ultra-precision machining of special-shaped surfaces. However, profile grinding produces a unique machining profile, and many random factors in the machining process lead to complex surface characteristics. In this study, the structural and probabilistic characteristics of the profile grinding of a special-shaped surface were analyzed, and a probabilistic algorithm for the forming and 3D characterization of special-shaped surfaces under profile grinding was developed. The forming process of a GH738 blade tenon tooth surface was considered as an example to demonstrate the algorithm. The comparison results showed that the simulation results had similar surface characteristics to the measurement results, and the relative error range of the 3D roughness parameter was 0.21 %-19.76 %, indicating an accurate prediction and characterization of the complex special-shaped surface under the action of multiple factors.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00467-9

Key words: Special-shaped surface, Profile grinding, Surface morphology, 3D characterization

Zhao-Qing Zhang, Kai-Ning Shi, Yao-Yao Shi, Yi-Hui Song, Zhe He, Ya-Song Pu. Study on a probabilistic algorithm for the forming and 3D characterization of special-shaped surfaces under profile grinding[J]. Advances in Manufacturing, 2024, 12(2): 288-299.

参考文献

1. Chen T, Miao Q, Xiong M et al (2022) On the residual stresses of turbine blade root of γ-TiAl intermetallic alloys induced by non-steady-state creep feed profile grinding. J Manuf Process 82:800–817
2. Kuang W, Miao Q, Ding W et al (2021) Fretting wear behaviour of machined layer of nickel-based superalloy produced by creep-feed profile grinding. Chin J Aeronaut 35(10):401–411
3. Grimmert A, Wiederkehr P (2021) Macroscopic process simulation of surface and profile grinding processes estimating forces for the production of turbine blades. Procedia CIRP 102:126–131
4. Zhao Z, Qian N, Ding W et al (2020) Profile grinding of DZ125 nickel-based superalloy: grinding heat, temperature field, and surface quality. J Manuf Process 57:10–22
5. Xi X, Ding W, Wu Z et al (2021) Performance evaluation of creep feed grinding of γ-TiAl intermetallics with electroplated diamond wheels. Chin J Aeronaut 34(6):100–109
6. Schieber C, Hettig M, Zaeh M et al (2021) Evaluation of approaches to compensate the thermo-mechanical distortion effects during profile grinding. Procedia CIRP 102:331–336
7. Guba N, Heinzel J, Heinzel C et al (2020) Grinding burn limits: Generation of surface layer modification charts for discontinuous profile grinding with analogy trials. CIRP J Manuf Sci Tec 31:99–107
8. Kuang W, Miao Q, Ding W et al (2021) Residual stresses of turbine blade root produced by creep-feed profile grinding: threedimensional simulation based on workpiece-grain interaction and experimental verification. J Manuf Process 62:67–79
9. He Y, Xiao G, Zhu S et al (2023) Surface formation in laserassisted grinding high-strength alloys. Int J Mach Tool Manu 186:104002. https://doi.org/10.1016/j.ijmachtools.2023.104002
10. Liu S, Xiao G, Lin O et al (2023) A new one-step approach for the fabrication of microgrooves on Inconel 718 surface with microporous structure and nanoparticles having ultrahigh adhesion and anisotropic wettability: laser belt processing. Appl Surf Sci 607:155108. https://doi.org/10.1016/j.apsusc.2022.155108
11. Sun C, Xiu S, Hong Y et al (2020) Prediction on residual stress with mechanical-thermal and transformation coupled in DGH. Int J Mech Sci 179:105629. https://doi.org/10.1016/j.ijmecsci.2020.105629
12. Li C, Piao Y, Zhang F et al (2023) Understand anisotropy dependence of damage evolution and material removal during nanoscratch of MgF₂ single crystals. Int J Extrem Manuf 5(1):015101. https://doi.org/10.1088/2631-7990/ac9eed
13. Li C, Hu Y, Zhang F et al (2023) Molecular dynamics simulation of laser assisted grinding of GaN crystals. Int J Mech Sci 239:107856. https://doi.org/10.1016/j.ijmecsci.2022.107856
14. Miao Q, Ding W, Kuang W et al (2021) Grinding force and surface quality in creep feed profile grinding of turbine blade root of nickel-based superalloy with microcrystalline alumina abrasive wheels. Chin J Aeronaut 34(2):576–585
15. Xiao Y, Wang S, Ma C et al (2022) Numerical modeling of material removal mechanism and surface topography for gear profile grinding. J Manuf Process 76:719–739
16. Feng H, Xiang D, Wu B et al (2019) Ultrasonic vibrationassisted grinding of blind holes and internal threads in cemented carbides. Int J Adv Manuf Tech 104(1/4):1357–1367
17. Lei X, Xiang D, Peng P et al (2021) Establishment of dynamic grinding force model for ultrasonic-assisted single abrasive high-speed grinding. J Mater Process Tech 300:117420. https://doi.org/10.1016/j.jmatprotec.2021.117420
18. Yang Z, He D, Wang S et al (2021) Determination of the grinding force on optical glass based on a diamond wheel with an ordered arrangement of abrasive grains. Int J Adv Manuf Tech 115(4):1237–1248
19. Zhao B, Guo X, Bie W et al (2020) Thermo-mechanical coupling effect on surface residual stress during ultrasonic vibration-assisted forming grinding gear. J Manuf Process 59:19–32
20. Li C, Li X, Wu Y et al (2019) Deformation mechanism and force modelling of the grinding of YAG single crystals. Int J Mach Tool Manu 143:23–37
21. Agarwal S, Rao P (2012) Predictive modeling of undeformed chip thickness in ceramic grinding. Int J Mach Tool Manu 56:59–68
22. Yu S, Yao P, Ye Z et al (2022) Simulation and experimental research of tool path planning on profile and surface generation of aspherical-cylindrical lens array by ultra-precision envelope grinding. J Mater Process Tech 307:117690. https://doi.org/10.1016/j.jmatprotec.2022.117690
23. Zhang Z, Yao P, Wang J et al (2019) Analytical modeling of surface roughness in precision grinding of particle reinforced metal matrix composites considering nanomechanical response of material. Int J Mech Sci 157/158:243–253
24. Hong Y, Sun C, Xiu S et al (2023) Strengthening surface generation mechanism of carburizing-assisted grinding. Tribol Int 180:108300. https://doi.org/10.1016/j.triboint.2023.108300
25. Li C, Piao Y, Meng B et al (2022) Phase transition and plastic deformation mechanisms induced by self-rotating grinding of GaN single crystals. Int J Mach Tool Manu 172:103827. https://doi.org/10.1016/j.ijmachtools.2021.103827
26. Chen H, Tang J, Zhou W (2013) Modeling and predicting of surface roughness for generating grinding gear. J Mater Process Tech 213(5):717–721
27. Zhou W, Tang J, Shao W (2020) Study on surface generation mechanism and roughness distribution in gear profile grinding. Int J Mech Sci 187:105921. https://doi.org/10.1016/j.ijmecsci.2020.105921
28. Yang Y, Wu Y, Tsai T (2022) An analytical method to control and predict grinding textures on modified gear tooth flanks in CNC generating gear grinding. Mech Mach Theory 177:105023. https://doi.org/10.1016/j.mechmachtheory.2022.105023
29. Setti D, Ghosh S, Rao P (2017) A method for prediction of active grits count in surface grinding. Wear 382/383:71–77
30. Younis MA, Alawi H (1984) Probabilistic analysis of the surface grinding process. T Can Soc Mech Eng 8(4):208–213
31. Jiang J, Ge P, Hong J (2013) Study on micro-interacting mechanism modeling in grinding process and ground surface roughness prediction. Int J Adv Manuf Tech 67(5/8):1035–1052
32. Yan Y, Zhang Z, Zhao B et al (2021) Study on prediction of three-dimensional surface roughness of nano-ZrO₂ ceramics under two-dimensional ultrasonic-assisted grinding. Int J Adv Manuf Tech 112(9/10):2623–2638

Study on a probabilistic algorithm for the forming and 3D characterization of special-shaped surfaces under profile grinding

Study on a probabilistic algorithm for the forming and 3D characterization of special-shaped surfaces under profile grinding

PDF

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 1

编辑推荐

Metrics

本文评价