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A new in-process material removal rate monitoring approach in abrasive belt grinding

机译:磨料带磨削的新型材料去除率监测方法

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摘要

Belt grinding is a material processing operation which is capable of producing parts to high dimensional accuracy, excellent finish surface, and surface integrity. Unlike turning or other metal cutting operations that use geometrically well-defined tools, belt grinding involves tool geometry and cutting actions that are not well defined. Therefore, it is quite difficult to obtain a comprehensive theoretical model to predict the grinding depth. As well known, the strain rate is very high in grinding with abrasive tools, which results in substantial heat produced in the shear zone. Sparks are produced when the hot chips thrown out during the process, get oxidized, and burn in the atmosphere. Spark is an inherent feature for most dry grinding process. An approach on material removal rate monitoring in belt grinding by spark field measurement is proposed. The size of the spark field is a visualized reflection of the number of chips instantaneous produced in grinding. Features of spark field related to the material removal rate are analyzed and quantified. With this method, the coupling between the grinding parameters is no need to be considered. Experimental results indicate that the changing of grinding parameters has a different impact on the feature values of the spark field. Feature values of the spark field, such as area, boundary, and density, show a tight correlation with the material removal rate. The resolution accuracy of spark features on the grinding depth is studied. The correct rate of the grinding depth identification can reach more than 95% for the area, and density features of the spark field with the resolution range greater than 10 mu m. The analysis indicates that the proposed method is effective and easy-to-accomplish for material removal rate monitoring in belt grinding.
机译:皮带磨削是一种材料加工操作,能够生产高尺寸精度,优异的表面表面和表面完整性。与使用几何定义的工具的转动或其他金属切割操作不同,皮带磨削涉及刀具几何形状和切割行动,这些动作并没有明确定义。因此,获得全面的理论模型是非常困难的,以预测研磨深度。众所周知,用磨料工具研磨应变速率非常高,这导致剪切区中产生的显着热量。当在过程中抛出的热芯片时,产生火花,得到氧化,并在大气中燃烧。 Spark是大多数干磨过程的固有功能。提出了一种采用火花场测量磨削磨削材料去除率监测的方法。 Spark场的尺寸是在研磨中瞬时产生的芯片数量的可视化反射。分析和量化与材料去除率相关的火花场的特征。利用这种方法,不需要考虑研磨参数之间的耦合。实验结果表明研磨参数的变化对火花场的特征值产生了不同的影响。 Spark场的特征值,例如区域,边界和密度,与材料去除速率紧密相关。研究了磨削深度上的火花特征的分辨率准确性。磨削深度识别的正确速率对于该区域可以达到95%以上,并且火花场的密度特征具有大于10μm的分辨率范围。分析表明,该方法在皮带研磨中的材料去除速率监测是有效且易于实现的。

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