Experimental Investigation of Ultrasonic Vibration-Assisted High-Speed Grinding for Bearing Ring Raceways
摘要
In response to the demands for efficiency, high precision, and high surface quality in bearing ring raceways, both high-speed grinding and ultrasonic vibration-assisted technologies are employed. However, the addition of the ultrasonic amplitude transformer increases the size of the grinding tool, which exacerbates dynamic imbalance during high-speed grinding, adversely affecting processing stability and environmental noise levels. To address these challenges, a transmission matrix model for a stepped ultrasonic amplitude transformer was developed and its geometric dimensions optimized. The validity of this model was verified using ANSYS software simulations and practical tooling tests. An experimental platform for ultrasonic vibration-assisted high-speed grinding was constructed, and on-site dynamic balancing technology was employed to adjust the rotor. This adjustment enabled the system to achieve a dynamic balance accuracy level of G0.4. Using the raceway of a deep groove ball bearing’s outer ring as the test workpiece, surface roughness and roundness were chosen as evaluation metrics. /Results indicated that ultrasonic grinding effectively reduces surface roughness and roundness in the workpiece. Additionally, the study found that increasing certain process parameters, specifically grinding wheel speed, feed speed, and ultrasonic amplitude, initially improves surface roughness and roundness but eventually leads to a decline in these qualities. Through experimental comparison, the optimal parameters were identified as a grinding wheel speed of 24,000 r/min, an ultrasonic amplitude of 3 μm, a workpiece speed of 150 r/min, a feed speed of 0.15 mm/min, and a grinding depth of 50 μm. The results indicate that ultrasonic vibration-assisted high-speed grinding improves average surface roughness by approximately 41.49% and roundness by about 32.02% compared to conventional high-speed grinding techniques.