基于随机过程的钎焊金刚石磨抛盘磨损可靠性

Wear reliability of brazed diamond wheel based on stochastic process

  • 摘要: 为实现高强度钢表面高效磨抛加工,设计一种钎焊金刚石磨抛盘,给出基体的结构,并对摩擦和热相互作用下磨具磨损可靠性进行了预测。首先,通过磨抛轨迹和接触区域特征建立钎焊金刚石磨抛盘材料去除函数模型;然后,在传统的磨损分析模型中引入白噪声代表磨抛过程的动态和随机因素,应用维纳过程理论和极限状态方程,建立了钎焊金刚石磨具磨粒磨损的动态可靠性模型,并给出了模型中重要统计特征参数的估计方法;最后,以钎焊金刚石磨抛盘磨抛AH32碳素钢为例进行了磨粒磨损可靠度和寿命特征的具体计算。结果表明,连续磨抛下磨抛盘的平均寿命达到15 h以上,可靠度曲线先缓慢下降后剧烈下降再缓慢下降;旋转速度、进给速度、磨削深度、磨料粒度等工艺参数对磨具的寿命有着重要影响,钎焊金刚石磨抛盘的可靠度与旋转速度、进给速度和磨削深度的乘积呈正比关系。该研究可为先进焊接磨具的定量寿命评估和强度优化设计提供了理论基础。

     

    Abstract: In order to achieve high efficiency grinding of high strength steel surface, the structure of a brazed diamond grinding disc was designed, and the wear reliability of abrasive tool under the interaction of friction and heat was predicted. Firstly, the material removal function model of brazed diamond grinding disc was established by grinding trajectory and contact zone characteristics. Then, white noise was introduced into the traditional wear analysis model to represent the dynamic and stochastic factors of grinding process. The wear dynamic reliability model of brazed diamond wheel was established by applying Wiener process theory and limit state equation. The estimation method of important statistical characteristic parameters in the model was given. Finally, the abrasive wear reliability and life characteristics of brazed diamond wheel grinding AH32 carbon rigid were calculated. The results showed that the average service life of the grinding disc under continuous grinding was more than 15 h, and the reliability curve first decreased slowly, then sharply, and then slowly with time. The process parameters such as rotational speed, feed speed, grinding depth and abrasive grain size had important effects on the life of abrasive tool. The reliability of brazed diamond grinding disc was directly proportional to the product of rotational speed, feed speed and grinding depth. This study could provide theoretical basis for quantitative life assessment and strength optimization design of advanced welding abrasive tools.

     

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