Grinding Wheel Modeling and Numerical Simulation in Grinding of Nickel-based Alloy via Discrete Element Method
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摘要: 为探究镍基合金在磨削加工中的材料去除机理,采用圆弧角度随机切分法,对砂轮表层磨粒进行了轮廓、分布的几何建模;采用平行键粘结线性标定法,对镍基合金材料进行了离散元模型校准;建立了砂轮磨粒磨削镍基合金加工的动态仿真。仿真结果表明:磨削过程中,磨削力存在动态波动;磨削切向力、法向力随着砂轮表面磨粒轮廓边数增加而减小;磨削切向力、法向力随着砂轮旋转速度增加而减小,数值模拟方法和结果对镍基合金磨削加工过程材料去除机理研究具有一定参考价值。Abstract: To explore the material removal mechanism in grinding of nickel-based alloy, the external profile and distribution of grits on the surface of the grinding wheel is geometrical modeled with the random arc segmentation method. By using the parallel bond bonding linear calibration method, the discrete element model for nickel-based alloy is calibrated; a dynamic simulation test of nickel-based alloy grinding is established with abrasive grains. The simulation results show that the grinding force fluctuates dynamically and the tangential force and normal force decrease with the increasing of grinding grain edges. With the increasing of grinding wheel speed, the tangential force and normal force are decreased. The simulation methods and results have a reference for studying the material removal mechanism during the grinding of nickel-based alloys.
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Key words:
- nickel-based alloy /
- geometrical modeling /
- discrete element /
- dynamic calibration
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表 1 改变平行键有效模量参数实验表
序号 参数 取值 1 Ec/GPa 100, 150, 200, 250, 300, 350, 400, 450, 500 2 kn/ks 1.5 3 σc/MPa 5 000 4 τc/MPa 1 000 5 μ 0.7 表 2 改变平行键刚度比仿真参数表
序号 参数 取值 1 Ec/GPa 223.89 2 kn/ks 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5 3 σc/MPa 5 000 4 τc/MPa 1 000 5 μ 0.7 表 3 改变平行键的粘结切向强度与抗拉强度比仿真参数表
序号 Ec/GPa kn/ks σc/MPa τc/MPa μ 1 223.89 4.722 2 500 500 0.7 2 223.89 4.722 3750 750 0.7 3 223.89 4.722 5 000 1 000 0.7 4 223.89 4.722 6 250 1 250 0.7 5 223.89 4.722 7 500 1 500 0.7 6 223.89 4.722 8 750 1 750 0.7 7 223.89 4.722 10 000 2 000 0.7 表 4 微观参数正交数值表及宏观参数计算结果
序号 A B C D E a b c 1 200 3.5 3 000 800 0.4 155 21 1 100 2 220 4.0 3 500 1 000 0.5 153 23 1 408 3 240 4.5 4 000 1 200 0.6 150 25 1 713 4 260 5.0 4 500 1 400 0.7 152 26 2 027 5 200 3.5 3 500 1 200 0.7 174 21 1 547 6 220 4.0 3 000 1 400 0.6 171 23 1 335 7 240 4.5 4 500 800 0.5 165 25 1 237 8 260 5.0 4 000 1 000 0.4 158 27 1 514 9 200 3.5 4 000 1 400 0.5 190 21 1 766 10 220 4.0 4 500 1 200 0.4 180 23 1 695 11 240 4.5 3 000 1 000 0.7 185 25 1 347 12 260 5.0 3 500 800 0.6 176 26 1 256 13 200 3.5 4 500 1 000 0.6 201 21 1 384 14 220 4.0 4 000 800 0.7 197 23 1 169 15 240 4.5 3 500 1 400 0.4 195 25 1 546 16 260 5.0 3 000 1 200 0.5 196 28 1 352 表 5 GH4169离散元模型与实测力学性能对比
力学特性参数 文献结果 离散元模拟结果 相对误差 弹性模量Et/GPa 204 196 3.9% 泊松比υ 0.3 0.28 6.7% 抗拉强度σt/MPa 1280 1352 5.6% 表 6 磨削仿真加工参数表
参数 参数取值 磨粒形状的边数n 3, 5, 7, 9 工件进给速度Vw/(mm·s-1) 50 磨削深度ap/μm 20 砂轮线速度Vs/(m·s-1) 10, 20, 30, 40 -
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