目的 解决砂轮磨削硬脆光学元件过程中形成的气障层阻碍磨削液进入,导致冷却效率低、润滑性能弱等问题,探究结构化砂轮对磨削区气流场的影响规律,优化砂轮表面结构以提升磨削液利用率,从而降低磨削力和磨削温度。方法 采用计算流体动力学仿真（CFD）与磨削试验相结合的方法,建立普通砂轮及直槽/斜槽/V型槽结构化砂轮气流场仿真三维模型,基于仿真优化结果制备青铜结合剂金刚石斜槽砂轮,对熔石英工件进行磨削加工试验验证。结果 气流场仿真结果表明,斜槽结构化砂轮工件表面正负压峰值绝对值之和最小。磨削加工试验结果表明,斜槽砂轮能有效降低磨削力和磨削温度,在500~2 000 r/min的转速范围内,斜槽砂轮法向磨削力降低了28.7%~41.5%,磨削温度降低了8%~20.2%,在100~400 μm的磨削深度范围下,斜槽砂轮法向磨削力降低了33.6%~40.9%,磨削温度降低了17.2%~19.3%。结论 斜槽结构化砂轮能有效削弱气障层强度,磨削区入口处未出现明显返流,试验证明斜槽砂轮可以提升磨削液利用率,有效改善熔石英元件的磨削加工性能,为光学元件低损伤加工提供了新方案。
Abstract
During the grinding of hard and brittle optical components with grinding wheels, the high-speed rotation forms an air barrier layer that prevents the grinding fluid from penetrating into the grinding zone, resulting in insufficient cooling and poor lubrication. The work aims to address this issue by investigating the influence of a textured grinding wheel on the airflow field in the grinding zone, optimizing the surface structure of the grinding wheel to improve the utilization of grinding fluid, thereby reducing the grinding force and temperature. Computational fluid dynamics (CFD) simulations and grinding experiments were combined to establish three-dimensional models of conventional grinding wheels and structured grinding wheels with straight grooves, helical grooves, and V-shaped grooves to simulate the airflow field distribution. Based on the simulation results, a bronze-bond diamond helical-grooved grinding wheel was fabricated and tested on a grinding machine using fused quartz workpieces. The simulation results of the airflow field showed that the sum of the absolute values of the positive and negative peak pressure on the surface of the workpiece of the helical-grooved structured grinding wheel was the smallest. The grinding test results indicated that the helical-grooved grinding wheel effectively reduced both the grinding force and temperature. Within a rotational speed range of 500-2 000 r/min, the normal grinding force decreased by 28.7%-41.5%, and the grinding temperature dropped by 8%-20.2%. Similarly, under a grinding depth range of 100-400 μm, the normal grinding force was reduced by 33.6%-40.9%, while the grinding temperature decreased by 17.2%-19.3%. The helical-grooved structured grinding wheel effectively weakens the air barrier and eliminates noticeable return flow at the grinding zone inlet. It significantly improves grinding fluid utilization and enhances the grinding performance of fused quartz components. This study provides a new solution for low-damage machining of optical elements.
关键词
结构化砂轮 /
气流场 /
磨削加工 /
数值模拟 /
光学加工
Key words
structured grinding wheel /
airflow field /
grinding /
numerical simulation /
optical processing
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基金
福建省自然科学基金（2025J01052）; 厦门市自然科学基金（3502Z202571001）
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