Development of CAM system for automatic compound dressing of superabrasive grinding wheels
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摘要: 为了使复合修整方法中的多种工艺更系统地整合，提高成形砂轮的修整效率，结合自主研制的激光–机械复合修整装备，开发一套CAM系统，可根据不同砂轮截面形状，自动规划多工艺、多修整策略下的修整轨迹，计算平面三轴联动修整刀路，自动生成加工代码，同时设计可视化界面仿真加工过程。对青铜结合剂金刚石砂轮进行修整试验，结果表明：该系统可在保证机床不发生碰撞和过切的情况下，生成激光粗修、半精修及机械精修的加工程序，大幅提高复合修整方法的编程效率，修整后的砂轮轮廓误差在9.1 µm以内，圆跳动误差为6.1 µm。
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关键词:
- 成形砂轮 /
- 激光–机械自动化复合修整 /
- 计算机辅助制造 /
- 轨迹规划
Abstract: In order to integrate various processes in composite dressing method more systematically and improve dressing efficiency of forming grinding wheel, a CAM system was developed by combining self-developed laser and mechanical composite dressing equipment. According to different grinding wheel section shapes, the system can automatically plan dressing trajectory under multi-process and multi-dressing strategy, calculate planar three-axis linkage dressing tool path, automatically generate machining code, and design visual interface to simulate machining process. The dressing experiment of bronze bonded diamond grinding wheel was completed. The results show that the system can generate laser rough repair, semi-finishing repair and mechanical finishing machining program without collision and overcutting, and greatly improve the programming efficiency of composite dressing method. After dressing, the grinding wheel profile error was within 9.1 µm and the runout error was 6.1 µm. -
表 1 机床性能参数
Table 1. Machine tool performance parameters
参数名称 数值 U、V、Z行程 $ {l}_{\mathrm{m}\mathrm{a}\mathrm{x}} $ / mm 200；200；300 定位精度 $ {P}_{\mathrm{a}\mathrm{c}\mathrm{c}} $ / μm ±2 重复精度 $ {R}_{\mathrm{a}\mathrm{c}\mathrm{c}} $ / μm ±2 W轴偏转角度 $ \theta $ / (°) ±50 角度误差 $ \theta $er 6″ 主轴Ⅰ转速 $S$1 / (r·min−1) 0～4 000 主轴Ⅱ转速 $S$2 / (r·min−1) 0～3 000 
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表 2 原材料属性
Table 2. Properties of raw materials
参数名称 规格或数值 结合剂 青铜 磨粒 金刚石 粒度 d50 / μm 150 外径（毛坯）$ D $ / mm 125 内径 $ {d}_{1} $ / mm 80 厚度 d2 / mm 18 径向跳动 $ {C}_{\mathrm{e}\mathrm{r}\mathrm{r}} $ / μm 450
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表 3 激光粗修参数
Table 3. Laser roughing parameters
参数名称 参数值 输出功率 P1 / W 200 重复频率 f / kHz 100 砂轮转速 n / (r·min−1) 240 进给速度 $ {V}_{\mathrm{f}} $ / (mm·min−1) 3
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表 4 激光半精修参数
Table 4. Laser semi-finishing parameters
参数名称 参数值 输出功率 $ P $ / W 80 重复频率$ f $ / kHz 100 砂轮转速 $ n $ / (r·min−1) 240 进给速度 ${V}_{{\rm{n}}}$ / (mm· min−1) 1
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表 5 机械修整参数
Table 5. Parameters of machining
参数名称 参数值 砂轮转速 $ {n}_{1} $ / (r·min−1) 1 000 刀具转速 $ {n}_{2} $ / (r·min−1) 1 500 切削深度 $ {a}_{\mathrm{p}} $ / μm 5，2，1 进给速度 $ {V}_{\mathrm{f}} $ / (mm·min−1) 3
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