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An improved chip-thickness model for surface roughness prediction in robotic belt grinding considering the elastic state at contact wheel-workpiece interface

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Abstract

The elastic state at contact wheel–workpiece interface is a critical issue during robotic belt grinding process that significantly influences the finishing profile accuracy. Establishing a reasonable undeformed chip-thickness (UCT) model that suits to this operation is considered a feasible approach to clarify the cutting mechanisms. In the present paper, an elastic state–driven robotic belt grinding chip-thickness model is established to predict the workpiece surface roughness. In this new model, the combined modulus of elasticity of the contact wheel is calculated according to the formula of Young’s modulus, and the exponent with respect to the effects of linear and nonlinear deflection is further determined based on the energy balance hypothesis. Experiments are conducted to verify the reasonability of the improved chip-thickness model from the perspective of surface roughness, and the findings are likely to clarify the differences in material removal mechanism between wheel grinding and robotic belt grinding essentially.

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Abbreviations

a e :

Depth of cut (μm)

b s :

Width of grinding contact wheel (mm)

C :

Number of active grits per unit area (mm−2)

d eq :

Equivalent diameter of the contact wheel (mm)

d g :

Equivalent spherical diameter of abrasives (mm)

d L :

Shape variable of the contact wheel under action of normal belt grinding force Fn

d L1 :

Shape variable of the aluminum alloy core under action of normal belt grinding force Fn

d L2 :

Shape variable of the rubber under action of normal belt grinding force Fn

e s :

Specific belt grinding energy (J/mm3)

E 1 :

Modulus of elasticity of the contact wheel (GPa)

E 2 :

Modulus of elasticity of the workpiece (GPa)

E 11 :

Modulus of elasticity of aluminum alloy (GPa)

E 12 :

Modulus of elasticity of rubber (GPa)

f :

Fraction of abrasives that actively cut in belt grinding

F n :

Normal belt grinding force (N)

F t :

Tangential belt grinding force (N)

h m :

Maximum chip thickness by the existing model (μm)

h ′ m :

Maximum chip thickness by the improved model (μm)

l c :

Contact length between the contact wheel and workpiece (mm)

n :

Exponent

r :

Ratio of mean chip width to thickness

r 1 :

Radius of aluminum alloy core (mm)

r 2 :

Radius of contact wheel (mm)

Ra :

Center-line average value of surface roughness (μm)

Ra′ :

Surface roughness estimated with the existing chip-thickness model (μm)

Ra″ :

Surface roughness estimated with the improved chip-thickness model (μm)

S :

Area of deformation of the aluminum alloy surface (mm2)

v :

Volume fraction of abrasives in belt grinding

v s :

Contact wheel speed (m/s)

v w :

Workpiece (robot feed) speed (mm/s)

V c :

Volume of each chip (mm3)

△1 :

Roughness deviation of the existing model

△2 :

Roughness deviation of the improved model

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Funding

The authors received financial support from the National Nature Science Foundation of China (Nos. 51675394, 51975443), the National Key Research and Development Program of China (No. 2017YFB1303403), the State Key Laboratory of Digital Manufacturing Equipment and Technology (No. DMETKF2018018), and the “111” Project (No. B17034).

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Authors and Affiliations

  1. Hubei Key Laboratory of Advanced Technology for Automotive Components, Wuhan University of Technology, Wuhan, 430070, China

    Chao Qu, Yuanjian Lv & Dahu Zhu

  2. Hubei Collaborative Innovation Center for Automotive Components Technology, Wuhan University of Technology, Wuhan, 430070, China

    Chao Qu, Yuanjian Lv & Dahu Zhu

  3. State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, 430074, China

    Zeyuan Yang, **aohu Xu & Sijie Yan

Authors
  1. Chao Qu
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  2. Yuanjian Lv
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  3. Zeyuan Yang
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  4. **aohu Xu
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  5. Dahu Zhu
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  6. Sijie Yan
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Corresponding author

Correspondence to Dahu Zhu.

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Qu, C., Lv, Y., Yang, Z. et al. An improved chip-thickness model for surface roughness prediction in robotic belt grinding considering the elastic state at contact wheel-workpiece interface. Int J Adv Manuf Technol 104, 3209–3217 (2019). https://doi.org/10.1007/s00170-019-04332-7

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  • DOI: https://doi.org/10.1007/s00170-019-04332-7

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