超声振动三维螺线磨削表面微观作用机理研究

Aiming at meeting the significantly increasing demand for optical crystal components with high quality surface in the cutting-edge area of civil and military application, a new ultrasonic assisted spatial helical grinding method was proposed recently. But the theoretical research of the method is not yet mature. (1) This study intends to establish the mathematical model of surface microstructure generation in three-dimensional spiral ultrasonic vibration grinding. And reveal the mechanism of different grinding and ultrasonic vibration parameters on interference action of grain paths. As well as clarify the surface generation mechanism under joint action of ultrasonic vibration and grinding parameters. (2) A new method that used to monitor grinding wheel wear states will be proposed based on power spectral density calculation and the fractal theory. This work will establish a surface static and dynamic model of grinding wheel, and reveal the effect of ultrasonic vibration on the influence of the wear conditions of a diamond wheel surface. Then, the failure criterion of grinding wheel under ultrasonic vibration will be established, and the prediction model of grinding wheel residual life will be proposed. (3) The related experiments will be carried out to verify the correctness and feasibility of the simulation model. The research results will lay a theoretical foundation for the application and promotion of three-dimensional spiral ultrasonic vibration grinding of optical materials.

针对军用和民用等尖端技术领域对光学晶体元件高质量表面需求日趋迫切的现状，近年来一种磨粒路径为空间螺旋线的超声振动磨削新方法被提出，但该方法的理论研究尚不成熟。（1）本研究拟建立超声振动三维螺线磨削表面微观形貌创成的数学模型，揭示不同超声振动与不同磨削参数综合作用下磨粒空间螺线切削路径相互干渉作用机制，阐明超声振动与磨削参数联合作用下其表面创成机制。（2）提出一种新的基于功率谱密度分形方法用于监测砂轮磨损状态；建立砂轮动态仿真模型，揭示在复杂超声振动冲击作用下动态砂轮磨损过程对磨削表面微观形貌创成的影响规律，从而建立超声振动作用下砂轮失效准则，提出砂轮剩余寿命预测模型；（3）进行相关试验来验证仿真模型的正确性与可行性，课题研究成果将为超声振动三维螺线磨削光学材料的应用与推广奠定理论基础。

针对军用和民用等尖端技术领域对光学晶体元件高质量表面需求日趋迫切现状，一种新颖的超声振动螺线磨削方法被提出，本课题深入研究了超声振动三维螺线磨削表面微观创成机理。建立了超声振动螺线磨削表面微观形貌的数学模型，揭示了多参数耦合作用下对表面微观形貌的影响规律；首次提出了“pass by pass”的可视化理念，将超声振动磨削的材料去除过程通过“pass by pass” 仿真可视化，使得复杂的加工过程信息更容易被理解和分析。实现了动态观测超声振动磨削的材料去除过程，揭示其内在的加工机理为构建关于光学晶体超声振动螺线磨削表面控形技术提供理论基础，为设计和制造具有自主知识产权的重要加工基础元件——高性能超声振动装置提供了技术支持；提出了不受尺度限制的超声振动螺线磨削金刚石砂轮表面形貌的综合表征方法，重点解决超声振动三维螺线磨削金刚石砂轮磨损情况的在线监测和预测问题；采用功率谱密度方法对超声螺线磨削砂轮表面形貌进行分形维数计算，揭示了砂轮表面微观几何形貌拓补结构与其磨损机制之间的联系。在此基础上探讨多参数耦合作用下对砂轮表面不同磨损形态的影响机制，研究了在复杂超声振动冲击作用下动态砂轮磨损过程对磨削表面微观形貌的影响规律，保证砂轮的使用性能和可靠性。研究结果为实现超声振动三维螺线磨削加工技术的广泛应用提供理论指导和技术支持。