The surfaces of brittle materials are susceptible to defects such as scratches,cracks,and chipping during con-ventional grinding processes,which significantly compromise surface quality and service performance.A flexi...The surfaces of brittle materials are susceptible to defects such as scratches,cracks,and chipping during con-ventional grinding processes,which significantly compromise surface quality and service performance.A flexible ball-end body-armor-like abrasive tool(BAAT)can effectively remove micro-convex peaks from the surfaces of brittle materials by employing a high tangential grinding force and a low normal grinding force,thereby achieving nano-level surface roughness and ultra-smooth mirror finishes.However,the surface contact me-chanism,pressure distribution pattern,and grinding force behavior between BAAT and workpiece remain in-adequately understood.This study examines the mechanism of liquid film formation and the distribution pattern of elastohydrodynamic pressure in high-shear and low-pressure grinding areas,drawing on the theories of elastohydrodynamic lubrication,non-Newtonian fluid dynamics,and material mechanics.A high-shear low-pressure grinding force model,which incorporates elastohydrodynamic liquid film thickness and abrasive grain size,was developed.The effects of the main grinding parameters(normal load,spindle rotational speed,and abrasive grain size)on the tangential grinding force were investigated through the processing of lithium niobate crystals using an intelligent precision-grinding system.The experimental results indicated that the relative error between the predicted and experimental values was 10.74%,thereby confirming the accuracy of the grinding force model.This study advances the understanding of elastohydrodynamic lubrication mechanisms in abrasive machining and provides a crucial theoretical foundation for the application of flexible ball-end BAAT.展开更多
基金Supported by National Natural Science Foundation of China(Grant Nos.52575516,51875329)Taishan Scholar Special Foundation of Shandong Province(Grant Nos.tstp20240826,tsqn201812064)+2 种基金Shandong Provincial Natural Science Foundation(Grant No.ZR2023ME112)Key Research and Development Project of the Ningxia Hui Autonomous Region(Grant No.2024BEE02019)Innovation Capacity Improvement Programme for High-tech SMEs of Shandong Province(Grant Nos.2022TSGC1333,2022TSGC1261).
文摘The surfaces of brittle materials are susceptible to defects such as scratches,cracks,and chipping during con-ventional grinding processes,which significantly compromise surface quality and service performance.A flexible ball-end body-armor-like abrasive tool(BAAT)can effectively remove micro-convex peaks from the surfaces of brittle materials by employing a high tangential grinding force and a low normal grinding force,thereby achieving nano-level surface roughness and ultra-smooth mirror finishes.However,the surface contact me-chanism,pressure distribution pattern,and grinding force behavior between BAAT and workpiece remain in-adequately understood.This study examines the mechanism of liquid film formation and the distribution pattern of elastohydrodynamic pressure in high-shear and low-pressure grinding areas,drawing on the theories of elastohydrodynamic lubrication,non-Newtonian fluid dynamics,and material mechanics.A high-shear low-pressure grinding force model,which incorporates elastohydrodynamic liquid film thickness and abrasive grain size,was developed.The effects of the main grinding parameters(normal load,spindle rotational speed,and abrasive grain size)on the tangential grinding force were investigated through the processing of lithium niobate crystals using an intelligent precision-grinding system.The experimental results indicated that the relative error between the predicted and experimental values was 10.74%,thereby confirming the accuracy of the grinding force model.This study advances the understanding of elastohydrodynamic lubrication mechanisms in abrasive machining and provides a crucial theoretical foundation for the application of flexible ball-end BAAT.
