Surface roughness model of ultrasonic vibration-assisted grinding GCr15SiMn bearing steel and surface topography evaluation

doi:10.1007/s40436-024-00522-z

Advances in Manufacturing ›› 2025, Vol. 13 ›› Issue (1): 88-104.doi: 10.1007/s40436-024-00522-z

Surface roughness model of ultrasonic vibration-assisted grinding GCr15SiMn bearing steel and surface topography evaluation

Xiao-Fei Lei¹, Wen-Feng Ding¹, Biao Zhao¹, Dao-Hui Xiang², Zi-Ang Liu¹, Chuan Qian¹, Qi Liu³, Dong-Dong Xu⁴, Yan-Jun Zhao⁵, Jian-Hui Zhu⁵

1. National Key Laboratory of Science and Technology on Helicopter Transmission, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, People's Republic of China;
2. School of Mechanical and Power Engineering, Henan Polytechnic University, Jiaozuo 454000, Henan, People's Republic of China;
3. Centre for Precision Manufacturing, University of Strathclyde, Glasgow, UK;
4. School of Mechanical Engineering, Tongji University, Shanghai 450001, People's Republic of China;
5. State Key Laboratory for High Performance Tools, Zhengzhou Research Institute for Abrasives and Grinding Co. LTD, Zhengzhou 201804, People's Republic of China

收稿日期:2023-12-14 修回日期:2024-01-16 发布日期:2025-02-26
通讯作者: Dao-Hui XIANG,E-mail:dhxiang@hpu.edu.cn E-mail:dhxiang@hpu.edu.cn
作者简介:Xiao-Fei Lei is currently a Ph.D. candidate of Mechanical Engineering at Nanjing University of Aeronautics and Astronautics, P.R. China. His research interest is ultra precision grinding technology and equipment.
Wen-Feng Ding is currently a Professor of Mechanical Engineering and Doctoral Supervisor at Nanjing University of Aeronautics and Astronautics, P.R. China. His research interests include high-efficiency and precision grinding technology and equipment, machining process simulation and control technology, etc.
Biao Zhao is currently an associate Professor of Mechanical Engineering and Doctoral Supervisor at Nanjing University of Aeronautics and Astronautics, P.R. China. His research interests include high-efficiency and precision grinding technology and equipment, superhard abrasive tools, etc.
Dao-Hui Xiang is currently a Professor of Mechanical Engineering and Doctoral Supervisor at Henan Polytechnic University, P.R. China. His research interests include precision and ultra precision (special) machining technology, intelligent manufacturing technology, coating theory and diamond technology, tool technology and superhard abrasives.
Zi-Ang Liu is currently a Master candidate of Mechanical Engineering at Nanjing University of Aeronautics and Astronautics, P.R. China. His research interest is preparation technology of ultrasonic brazing tools.
Chuan Qian is currently a Master candidate of Mechanical Engineering at Nanjing University of Aeronautics and Astronautics, P.R. China. Her research interest is grinding technology of difficult-to-cut materials.
Qi Liu is currently an assistant professor at University of Strathclyde, Glasgow, UK. His main research interest is precision manufacturing.
Dong-Dong Xu is currently an assistant professor at Tongji University, Shanghai. His main research interest is advanced manufacturing technology for fatigue damage and repair of aviation components.
Yan-Jun Zhao is currently professor and director at State Key Laboratory for High Performance Tools, Zhengzhou Research Institute for Abrasives and Grinding Co. LTD, China. His main research interest is research on the design of superabrasive tools.
Jian-Hui Zhu is currently professor at State Key Laboratory for High Performance Tools, Zhengzhou Research Institute for Abrasives and Grinding Co. LTD, China. His main research interest is the grinding technology of high-performance grinding tools.
基金资助:
This work was financially supported by the National Natural Science Foundation of China (Grant Nos. 92160301, 92060203, 52175415, and 52205475), the Science Center for Gas Turbine Project (Grant Nos. P2022-AB-IV-002-001 and P2023-B-IV-003-001), the Natural Science Foundation of Jiangsu Province (Grant No. BK20210295), the Superior Postdoctoral Project of Jiangsu Province (Grant No. 2022ZB215), and the National Key Laboratory of Science and Technology on Helicopter Transmission (Nanjing University of Aeronautics and Astronautics) (Grant No. HTL-A-22G12).

Surface roughness model of ultrasonic vibration-assisted grinding GCr15SiMn bearing steel and surface topography evaluation

Xiao-Fei Lei¹, Wen-Feng Ding¹, Biao Zhao¹, Dao-Hui Xiang², Zi-Ang Liu¹, Chuan Qian¹, Qi Liu³, Dong-Dong Xu⁴, Yan-Jun Zhao⁵, Jian-Hui Zhu⁵

1. National Key Laboratory of Science and Technology on Helicopter Transmission, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, People's Republic of China;
2. School of Mechanical and Power Engineering, Henan Polytechnic University, Jiaozuo 454000, Henan, People's Republic of China;
3. Centre for Precision Manufacturing, University of Strathclyde, Glasgow, UK;
4. School of Mechanical Engineering, Tongji University, Shanghai 450001, People's Republic of China;
5. State Key Laboratory for High Performance Tools, Zhengzhou Research Institute for Abrasives and Grinding Co. LTD, Zhengzhou 201804, People's Republic of China

Received:2023-12-14 Revised:2024-01-16 Published:2025-02-26
Contact: Dao-Hui XIANG,E-mail:dhxiang@hpu.edu.cn E-mail:dhxiang@hpu.edu.cn
Supported by:
This work was financially supported by the National Natural Science Foundation of China (Grant Nos. 92160301, 92060203, 52175415, and 52205475), the Science Center for Gas Turbine Project (Grant Nos. P2022-AB-IV-002-001 and P2023-B-IV-003-001), the Natural Science Foundation of Jiangsu Province (Grant No. BK20210295), the Superior Postdoctoral Project of Jiangsu Province (Grant No. 2022ZB215), and the National Key Laboratory of Science and Technology on Helicopter Transmission (Nanjing University of Aeronautics and Astronautics) (Grant No. HTL-A-22G12).

摘要/Abstract

摘要： It is necessary to improve the surface performance of bearing rings and extend the service life of bearings. In this study, ultrasonic vibration-assisted grinding (UVAG) was applied to process GCr15SiMn bearing steel, considering the effects of grinding-wheel wear, overlap of abrasive motion tracks under ultrasonic conditions, elastic yield of abrasives, and elastic recovery of the workpiece on the machined surface. In addition, a novel mathematical model was established to predict surface roughness (R_a). The proposed model was validated experimentally, and the predicted and experimental results showed similar trends under various processing parameters, with both within an error range of 12%-20%. The relationships between the machining parameters and R_a for the two grinding methods were further investigated. The results showed that increases in the grinding speed and ultrasonic amplitude resulted in a decrease in R_a, whereas increases in the grinding depth and workpiece speed resulted in an increase in R_a. Furthermore, the R_a values obtained using the UVAG method were lower than those of conventional grinding (CG). Finally, the influence of ultrasonic vibration on the surface topography was investigated. Severe tearing occurred on the CG surface, whereas no evident defects were observed on the ultrasonically machined surface. The surface quality was improved by increasing the ultrasonic amplitude such that it did not exceed 4 μm, and a further increase in ultrasonic amplitude deteriorated the surface topography. Nevertheless, this improvement was superior to that of the CG surface and was consistent with the variation in R_a.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00522-z

关键词: Surface roughness, Ultrasonic vibration-assisted grinding (UVAG), GCr15SiMn bearing steel, Mathematical model, Surface morphology

Abstract: It is necessary to improve the surface performance of bearing rings and extend the service life of bearings. In this study, ultrasonic vibration-assisted grinding (UVAG) was applied to process GCr15SiMn bearing steel, considering the effects of grinding-wheel wear, overlap of abrasive motion tracks under ultrasonic conditions, elastic yield of abrasives, and elastic recovery of the workpiece on the machined surface. In addition, a novel mathematical model was established to predict surface roughness (R_a). The proposed model was validated experimentally, and the predicted and experimental results showed similar trends under various processing parameters, with both within an error range of 12%-20%. The relationships between the machining parameters and R_a for the two grinding methods were further investigated. The results showed that increases in the grinding speed and ultrasonic amplitude resulted in a decrease in R_a, whereas increases in the grinding depth and workpiece speed resulted in an increase in R_a. Furthermore, the R_a values obtained using the UVAG method were lower than those of conventional grinding (CG). Finally, the influence of ultrasonic vibration on the surface topography was investigated. Severe tearing occurred on the CG surface, whereas no evident defects were observed on the ultrasonically machined surface. The surface quality was improved by increasing the ultrasonic amplitude such that it did not exceed 4 μm, and a further increase in ultrasonic amplitude deteriorated the surface topography. Nevertheless, this improvement was superior to that of the CG surface and was consistent with the variation in R_a.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00522-z

Key words: Surface roughness, Ultrasonic vibration-assisted grinding (UVAG), GCr15SiMn bearing steel, Mathematical model, Surface morphology

Xiao-Fei Lei, Wen-Feng Ding, Biao Zhao, Dao-Hui Xiang, Zi-Ang Liu, Chuan Qian, Qi Liu, Dong-Dong Xu, Yan-Jun Zhao, Jian-Hui Zhu. Surface roughness model of ultrasonic vibration-assisted grinding GCr15SiMn bearing steel and surface topography evaluation[J]. Advances in Manufacturing, 2025, 13(1): 88-104.

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Surface roughness model of ultrasonic vibration-assisted grinding GCr15SiMn bearing steel and surface topography evaluation

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