基于加工形貌数据聚类的单点金刚石磨削稳定性及工艺调控  

Stability and process control of single-diamond grinding based on clustering of processing morphology data

作　　者：徐鑫宇 贺先送 陈钊杰 张竞颖 杨林丰[1] 谢晋[1] XU Xinyu;HE Xiansong;CHEN Zhaojie;ZHANG Jingying;YANG Linfeng;XIE Jin(School of Mechanical and Automotive Engineering,South China University of Technology,Guangzhou 510640,China)

机构地区：[1]华南理工大学机械与汽车工程学院,广州510640

出　　处：《金刚石与磨料磨具工程》2025年第1期1-11,共11页Diamond & Abrasives Engineering

基　　金：国家自然科学基金(52375493);广东省基础与应用基础研究基金(2022A1515220053)。

摘　　要：硬质模具钢磨削过程中,加工深度的变化会引起磨削力变化,导致其加工状态不稳定。采用大颗粒单点金刚石磨削硬质模具钢,基于其加工表面的形貌特征分析磨削过程的动态特性及稳定性,探究工艺参数对加工效率和表面质量的影响,以实现其高效率高质量的磨削加工。首先,对单点金刚石磨削系统进行动力学建模,采用加速度传感器测量磨削振动信号并进行工作模态分析,求解磨削系统的固有频率和阻尼比。然后,基于不同加工工况的表面波纹度和表面粗糙度数据,关联进给深度和砂轮转速与稳定工况时的数据聚类,且与磨削稳定时的叶瓣图区域匹配,拟合出磨削系统刚度和磨削力系数,构建稳定磨削过程中的进给深度和砂轮转速实时调控区域。最后,通过模具钢的磨削实验验证及分析其加工效率和质量。结果表明:磨削过程的模态分析与加工表面形貌特征的聚类匹配能够映射磨削稳定域的加工工艺参数;在磨削稳定域内,采用更大的材料去除率可将模具钢的平均表面波纹度从1.203μm降低到0.635μm,平均表面粗糙度从0.267μm降低到0.143μm;且在相同的材料去除量下,磨削稳定域加工的模具钢表面粗糙度平均下降74%。因此,在加工过程中依据加工表面特征化的磨削稳定域实时调整进给深度和砂轮转速,可同时提高工件的加工质量和效率。Objectives:In the precision grinding process of hard mold steel workpieces,the subtle changes in machining depth can significantly cause dynamic changes in the magnitude and the direction of grinding forces,which directly lead to unstable machining conditions and affect machining accuracy and surface quality.To this end,the data clustering analysis is used to analyze the machining morphology data of the workpiece,and the stable single-point grinding of the workpiece is achieved through process control.Methods:Using large particle diamond single-point grinding for hard mold steel,the dynamic characteristics and the stability of the grinding process are analyzed based on the morphology characteristics of the diamond processing surface.The influences of the process parameters on diamond processing efficiency and surface quality are explored to achieve high-efficiency and high-quality diamond grinding.Firstly,the dynamic modeling of the single point diamond grinding system is carried out,and the grinding vibration signal is measured by an accelerometer.The working mode analysis is performed to solve the natural frequency and the damping ratio of the machining system.Then,using a laser confocal microscope to obtain surface waviness and surface roughness data under different processing conditions,the feed depth and the wheel speed are correlated with the data clustering under stable conditions,and matched with the blade diagram area under stable grinding conditions to fit the stiffness and the grinding force coefficients of the processing system.A real-time control area for feed depth and the wheel speed during the stable grinding process is constructed.Finally,the machining efficiency and the quality of the mold steel are verified and analyzed through grinding experiments.Results:The modal analysis of the grinding process and the clustering matching of the machined surface morphology features can map the machining process parameters in the stable domain of the grinding process.The working mode analysis method is appli

关 键 词：单点金刚石 磨削稳定性 聚类分析 表面质量 表面粗糙度 

分 类 号：TQ164[化学工程—高温制品工业] TG58[金属学及工艺—金属切削加工及机床] TG156