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<p>Nowadays, the spherical plain bearing performance can be effectively improved by the application of WC-10Co-4Cr coatings on the inner ring. However, as a difficult-to-process material, efficient and high-quality processing of the coating has consistently garnered great attention to industry. In this paper, a method for evaluating the machining results based on cup-wheel grinding trajectory analysis has been introduced, which aims to improve the grinding efficiency and surface roughness. Firstly, the geometry and kinematics of the machining process was theoretically analyzed and the grinding trajectories under different ratio <i>K</i> (tool rotation speed/workpiece rotation speed) were simulated. Then, the density (<i>ρ</i>) and standard deviation (SD) metrics were introduced to quantitatively evaluate the trajectory quality, and mathematical relationships with the ratio <i>K</i> were respectively fitted. Through the simulation results under different ratios, we found that integer ratio <i>K</i> tends to cause the trajectory duplication, while the non-integer ratio <i>K</i> is more likely to boost the trajectory density and distribution’s homogeneity. Experimental results indicated that the quality of the grinding trajectory has significant impact on the machining results. When the ratio <i>K</i> is an integer, the overlapping trajectories induced significant machining defects on the coating surface, the surface roughness (Ra) were all more than 0.15&#xa0;μm and the material removal rate (MRRs) were all less than 20&#xa0;mm<sup>3</sup>/min. When the ratio <i>K</i> is a non-integer, the improvement in the coating’s surface integrity was observed, accompanying with a notable reduction in Ra and a steady increase in MRRs. Finally, when <i>K</i> = 69.23, the ρ is the highest and SD is the lowest, the corresponding Ra decreased to 0.074&#xa0;μm and MRR was achieved 46.05&#xa0;mm<sup>3</sup>/min. The experimental results demonstrate that grinding trajectory evaluation method yields effective prediction of grinding efficiency and surface roughness, and the fitted mathematical models can also provide process guidance for other speed combinations.</p>

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The Grinding Efficiency and Surface Roughness Study of WC-10Co-4Cr Coating on the Spherical Plain Bearings Based on the Trajectory Analysis

  • 期刊论文

  • 发表日期：

    2025年4月10日

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  • Zhenyu Jiang,
  • Chen Jiang,
  • Guiyuan Pu,
  • Lingqi Wang,
  • Yixuan Zhang,
  • Yu Hao,
  • Xiaolan Hong

摘要

Nowadays, the spherical plain bearing performance can be effectively improved by the application of WC-10Co-4Cr coatings on the inner ring. However, as a difficult-to-process material, efficient and high-quality processing of the coating has consistently garnered great attention to industry. In this paper, a method for evaluating the machining results based on cup-wheel grinding trajectory analysis has been introduced, which aims to improve the grinding efficiency and surface roughness. Firstly, the geometry and kinematics of the machining process was theoretically analyzed and the grinding trajectories under different ratio K (tool rotation speed/workpiece rotation speed) were simulated. Then, the density (ρ) and standard deviation (SD) metrics were introduced to quantitatively evaluate the trajectory quality, and mathematical relationships with the ratio K were respectively fitted. Through the simulation results under different ratios, we found that integer ratio K tends to cause the trajectory duplication, while the non-integer ratio K is more likely to boost the trajectory density and distribution’s homogeneity. Experimental results indicated that the quality of the grinding trajectory has significant impact on the machining results. When the ratio K is an integer, the overlapping trajectories induced significant machining defects on the coating surface, the surface roughness (Ra) were all more than 0.15 μm and the material removal rate (MRRs) were all less than 20 mm3/min. When the ratio K is a non-integer, the improvement in the coating’s surface integrity was observed, accompanying with a notable reduction in Ra and a steady increase in MRRs. Finally, when K = 69.23, the ρ is the highest and SD is the lowest, the corresponding Ra decreased to 0.074 μm and MRR was achieved 46.05 mm3/min. The experimental results demonstrate that grinding trajectory evaluation method yields effective prediction of grinding efficiency and surface roughness, and the fitted mathematical models can also provide process guidance for other speed combinations.