基于轴承毛坯表面分析的磨削材料去除率模型与应用实验

目的 在轴承套圈磨削加工中，传统基于动力学模型建立的磨削材料去除率模型仅考虑了磨削工件-砂轮-机床三者的弹性变形，未考虑毛坯零件表面不规则变形对模型的影响，导致传统理论模型在实际磨削应用中的效果不佳。针对此问题，基于轴承套圈毛坯表面形状分析建立了新的磨削材料去除率模型，并进行了应用实验。方法 基于轴承套圈毛坯零件表面形状的工艺研究，针对粗磨阶段毛坯零件表面不规则形状和弹性变形对磨削加工及产品质量的影响，建立不同偏心圆数量的轴承套圈结构分析方法，并提出一种以分段函数形式的磨削材料去除率模型，该模型充分考虑了轴承套圈毛坯零件表面不规则变形和偏心圆形状对磨削材料去除的影响，可有效反映轴承套圈实际材料磨削去除过程。最后，通过大量实验对所建的分段函数形式的磨削材料去除率模型进行应用实验研究。结果 与传统磨削材料去除率模型GPSM相比，所建的以分段函数形式的磨削材料去除率模型MMRG的准确率提高了96%以上，该模型可有效在线量化分析毛坯表面不规则大小及偏心圆结构。结论 该模型对指导毛坯零件制造，保证磨削加工质量和磨削加工效率有着重要的理论指导意义。

Grinding Material Removal Rate Model and Application Experiment Based on Bearing Blank Surface Analysis

As one of the core parts of the bearing, the groove machining accuracy and surface quality of the bearing ring seriously affect the service life of the bearing. Grinding has become the main way of precision machining of the bearing ring because it can make the ground parts obtain high machining accuracy and small surface roughness value. In the actual grinding process of bearing ring, the surface deformation of rough parts made by turning and heat treatment will have an important impact on the removal of grinding materials. The traditional grinding material removal rate model based on dynamic model only considers the elastic deformation of grinding workpiece, grinding wheel and machine tool, but does not consider the effects of irregular surface deformation of rough parts on the model, this leads to the poor effect of the traditional theoretical model in practical grinding application. In view of the problem, a new grinding material removal rate model is established to experiment research based on the bearing ring surface shape analysis. Firstly, according to the manufacturing process of the bearing ring, the deformation law of blank parts was analyzed, that was, the grinding track of bearing ring blank parts was composed of multiple eccentric circles, and the theoretical basis for calculating the eccentric number of bearing ring was put forward. The variation law of grinding force and material removal rate in the actual grinding process was studied, which was affected by the irregular deformation and eccentricity of bearing ring. Secondly, aiming at the surface irregular shape, elastic deformation and material removal of rough parts in the rough grinding stage, a grinding material removal rate model in the form of piecewise function was proposed. The model fully considerred the effects of the surface irregular deformation and eccentric circle shape of bearing ring rough parts in the grinding stage, which could effectively reflect the actual grinding condition of bearing ring. Finally, the inner diameter and roundness of the bearing ring blank parts were measured, and the grinding monitoring experimental platform was built to collect the characteristic signals of each sensor in grinding. Through a large number of experiments, the grinding material removal rate model in the form of piecewise function was experimentally studied. The sensor signals in the full contact grinding stage between the grinding wheel and the workpiece were analyzed, and the correction method of the traditional grinding material removal rate model was proposed to make it more effective to reflect the grinding material removal rate of the bearing ring in the full contact grinding stage between the grinding wheel and the workpiece. Compared with the traditional grinding material removal rate model (GPSM), the grinding material removal rate model in the form of piecewise function established in this paper had higher accuracy (than 96%). The model can be used to quantify the eccentric surface of the bearing and the effective size of the eccentric ring in on-line grinding. The piecewise function model established in this paper fully considers the change of material removal rate of bearing ring in the actual grinding process, which can not only guide the production and manufacturing of bearing ring blank parts to a certain extent, but also has important significance to improve the grinding quality and grinding efficiency.