王龙, 杨理钧, 汪刘应, 唐修检, 刘顾. 基于力信号的砂轮磨削状态在线监测研究[J]. 工程科学学报. DOI: 10.13374/j.issn2095-9389.2024.03.09.003
引用本文: 王龙, 杨理钧, 汪刘应, 唐修检, 刘顾. 基于力信号的砂轮磨削状态在线监测研究[J]. 工程科学学报. DOI: 10.13374/j.issn2095-9389.2024.03.09.003
WANG Long, YANG Lijun, WANG Liuying, TANG Xiujian, LIU Gu. An online grinding process monitoring method of grinding wheel based on force signals[J]. Chinese Journal of Engineering. DOI: 10.13374/j.issn2095-9389.2024.03.09.003
Citation: WANG Long, YANG Lijun, WANG Liuying, TANG Xiujian, LIU Gu. An online grinding process monitoring method of grinding wheel based on force signals[J]. Chinese Journal of Engineering. DOI: 10.13374/j.issn2095-9389.2024.03.09.003

基于力信号的砂轮磨削状态在线监测研究

An online grinding process monitoring method of grinding wheel based on force signals

  • 摘要: 磨削过程监控是实现磨削加工智能化与保证制造质量的关键. 磨削力是磨削加工过程中一个重要的伴随信号特征,它直接跟砂轮磨损程度、磨削热、砂轮与工件接触状态等事件之间有着密切联系. 为了提升微晶刚玉砂轮磨削齿轮工艺的精密化、自动化与智能化水平,开展砂轮磨削状态在线监测与砂轮磨损机制研究,建立磨削力时频两域信号与砂轮–工件接触状态、砂轮磨损程度事件之间的内在关联,提出一种基于实时力信号的砂轮磨削状态的在线监测新方法. 同时,采用激光共聚焦显微镜与扫描电镜表征分析了微晶刚玉砂轮形貌蕴含的磨损机理. 研究表明,磨削力时域波谱的峭度、波形指标、峰值指标、脉冲指标等波形特征指标分布规律呈现为变切深磨削状态≥显著磨损砂轮的稳态磨削状态≥轻度磨损砂轮的稳态磨削状态>未接触状态的鲜明态势. 然而,磨削力幅频谱的峭度、脉冲指标两项波形特征值在不同磨削状态下的变化规律却与时域信号截然相反. 砂轮工作表面三维粗糙度随磨损演变呈现出先略微减小后增大的变化规律,而微晶刚玉磨粒的聚微晶结构使其拥有沿微晶界面呈现逐层解理剥落的更新自锐能力.

     

    Abstract: Grinding process monitoring is key to assessing the intelligence of grinding processing and ensuring manufacturing quality of the intended product. The grinding force in the grinding process is an important characteristic, and the grinding force signal has a close relationship with the degree of wheel wear, grinding heat, grinding wheel and workpiece contact state, and other entities. Therefore, the analysis of the grinding force signal using the time domain and frequency domain analysis methods can effectively reveal the grinding characteristics and wheel wear evolution mechanism in the gear grinding process. In this study, the microcrystalline corundum grinding wheel was used to conduct the profile grinding test on 20CrMnTi steel gears installed in vertical machining centers. A high-performance general-purpose dynamometer was used to collect the discrete time series data of the grinding force in real time; a confocal laser microscope and scanning electron microscope were used to observe the wear characteristics of the microcrystalline wheel surface; finally, a micrometer was used to measure the thickness of the wheel’s end-top surface to assess the degree of wheel wear in a quick and simple way. To improve the precision, automation, and intelligence level of the gear grinding process considering the microcrystalline corundum grinding wheel, online monitoring of the grinding process and wear mechanism of the grinding wheel was performed. The intrinsic correlation between the time-frequency domain signals of the grinding force, the contact status of the grinding wheel and workpiece, and the wear degree of the grinding wheel was established. Thus, in this study, a new online monitoring method for monitoring the grinding process of the grinding wheel was proposed based on real-time force signals. Meanwhile, the wear mechanism underlying the morphology of microcrystalline corundum grinding wheels was characterized and analyzed using laser confocal microscopy and scanning electron microscopy. The results showed that the distribution pattern of waveform characteristic indicators such as kurtosis, waveform index, peak index, and pulse index in the time domain spectrum of the grinding force showed a distinct trend of varying cutting depth grinding state ≥ steady-state grinding state of a significantly worn grinding wheel ≥ steady-state grinding state of a lightly worn grinding wheel > noncontact state. However, the variation of the two waveform characteristic values of the grinding force, amplitude spectrum and pulse indicator under different grinding states is completely opposite to that of the time domain signals. After assessing the three-dimensional roughness of the working surface of the grinding wheel, it is observed that there is a slight decrease and a subsequent rapid increase in the roughness of the working surface of the wheel with the evolution of wheel wear. The polycrystalline structure of the microcrystalline corundum abrasive particles gives them the ability to update and sharpen along the microcrystalline interface, showing layer-by-layer cleavage peeling.

     

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