Structured grinding wheel design method and system for efficient grinding of surface of structural array

Abstract

The invention discloses a structured grinding wheel design method and system for efficient grinding of the surface of a structural array, and the method comprises the steps: analyzing the characteristics of a target microstructure array, and determining the geometric parameters of a microstructure unit; establishing a geometric mapping model of the structured grinding wheel-microstructure array, and performing parameterized representation on three types of parameters representing the microstructure array, the grinding process and the structured grinding wheel; according to the kinematics equation of structured grinding, the combination of the structured grinding wheel and the grinding process parameters is inversely solved, and an initial solution is obtained; determining a feasible solution meeting objective conditions in combination with the machining capacity of machining equipment and the engineering experience of grinding experts; a plurality of groups of structured grinding wheels are prepared according to feasible solutions, a matched structured grinding process is combined, a structured grinding experiment is implemented, corresponding microstructure arrays are obtained, and the design of the structured grinding wheels and planning of the structured grinding process are completed by comparing and evaluating the machining effect of each group of microstructure arrays and determining a final solution.

Description

Technical Field

[0001] The present invention belongs to the technical field of mechanical processing, and in particular relates to a structured grinding wheel design method and system for efficient grinding of structure array surfaces. Background Art

[0002] Functional microstructured surfaces are surfaces with specific microstructures. These microstructures can regulate and optimize surface properties, such as optical, mechanical, biological, and wettability, thereby imparting specific functions to the surface. However, processing efficiency of microstructures has been a major factor limiting their development. Especially for applications requiring large-area microstructure arrays, such as machine tool guideways, ship hull surfaces, and aircraft wings, maximizing production efficiency while ensuring the processing quality of the microstructure arrays is a key development direction. Among the many methods for manufacturing microstructure arrays, structured grinding has attracted widespread attention due to its high processing efficiency and strong adaptability. Structured grinding is a machining method that utilizes a grinding wheel with a specific concave-convex structure on its surface. The grinding wheel moves according to set process parameters to remove material, thereby directly forming a regularly arranged microstructure array on the workpiece surface. In this method, the concave-convex structure of the structured grinding wheel surface and the grinding process parameters are crucial variables, directly influencing the form, size, and distribution of the microstructure array on the workpiece surface. In practical applications, people often first manufacture a specific structured grinding wheel and then adjust the structured grinding process to produce different forms of microstructured surfaces. However, although this structured grinding process is simple to operate, there is a problem, that is, the structured grinding wheel manufactured first may not meet the processing requirements of a specific microstructured surface. Therefore, it is very necessary to establish a customized structured grinding wheel design method for the target microstructured surface characteristics. It is possible to design a structured grinding wheel for a microstructured surface and plan a target-oriented technical route for a set of structured grinding processes. Summary of the Invention

[0003] In order to solve the problems existing in the prior art, the present invention provides a structured grinding wheel design method and system for efficient grinding of structure array surfaces, which is of great significance for correctly, reasonably and efficiently realizing the processing of target microstructure arrays.

[0004] To achieve the above object, the present invention provides the following solutions:

[0005] A method for designing a structured grinding wheel for efficient grinding of a structured array surface, the method comprising:

[0006] Analyze the concavity and symmetry of the target microstructure unit contour, determine the feasibility of the structured grinding method and make appropriate simplifications;

[0007] Analyze the microstructure unit contour graphic to obtain the size, characteristic points and characteristic line segments of the microstructure unit contour graphic;

[0008] The contact half-chord length of the grinding wheel is obtained according to the characteristic line segment, and the microstructure unit is divided into three areas: the bottom plane area A1, the cutting-in and cutting-out area A2, and the side wall area A3;

[0009] According to the contour of area A1, the contour of the top area with the largest radius of the structured grinding wheel is inversely solved;

[0010] The midpoints of the contours of the microstructure units in the A3 area along the grinding direction are connected to form the edges of the sidewall area A3 of the microstructure;

[0011] According to the description function of the edge of A3, the equation of the corresponding edge on the structured grinding wheel is solved inversely;

[0012] The extreme points in the x and y directions on the structured grinding wheel are connected in sequence to form the remaining curved surfaces of the convex part of the structured grinding wheel except for the top at the largest radius. At the same time, it is ensured that the abrasive on each curved surface only plays a supporting role and does not interact with the workpiece surface.

[0013] Several groups of corresponding structured grinding wheels were manufactured according to different characteristic line segment selection schemes. Process tests were carried out using specific grinding parameters. The processing results of the microstructure array were tested and evaluated, and the optimal group was selected as the final design scheme of the structured grinding wheel.

[0014] Preferably, analyzing the concavity and convexity of the target microstructure unit profile includes:

[0015] Along the grinding direction, i.e., the x-direction, the outline of the microstructure unit is topologically convex, that is, the line segment connecting any two points with equal y in the figure should be located within the figure. For figures that are concave along the grinding direction, the concave figure is analyzed by decomposing it into several convex figures.

[0016] Analyze the concavity and symmetry of the target microstructure unit contour, including:

[0017] If the figure is symmetrical only about the x-axis or the y-axis, the outline of the microstructure unit is simplified to 1 / 2 of the original figure about the symmetry axis; if the figure is symmetrical about both the x-axis and the y-axis, the outline of the microstructure unit is simplified to 1 / 4 of the original figure.

[0018] Preferably, analyzing the microstructure unit contour graphic to obtain the size, characteristic points, and characteristic line segments of the microstructure unit contour graphic includes:

[0019] Determine the maximum and minimum points along the y-axis L U With L D , L U With L DThe difference in the y-axis direction is Δy; if the extreme point in the y-axis direction is located on a line segment parallel to the x-axis, then the extreme point is not unique; determine the maximum point and the minimum point along the x-axis direction L R With L L , L R With L L The horizontal distance along the x direction is L x ; There are several vertices P1, P2, ..., P in the outline of the microstructure unit. n , if the graph is a smooth curve, the number of vertices is 0;

[0020] If the feature point L U With L D are all unique, and the characteristic line segment s f The length along the x-axis is l x Two line segments s fu and s fd , and the feature point L U and the characteristic line segment s below fd The distance between them is d U , where 0.5·Δy <d u <Δy, feature point L D and the characteristic line segment s located above fu The distance between them is d D , where 0.5·Δy <d d <Δy, so that the lengths of the two characteristic line segments meet the conditions, l x =2·l c , where l c is the contact half chord length between the grinding wheel and the workpiece during grinding; if at the characteristic point L U With L D In the equation, only one point is unique, then only one characteristic line segment that meets the requirements can be found. If two characteristic points L U With L D If they are not unique, then find countless characteristic line segments that meet the requirements;

[0021] On the characteristic line segment s f After confirmation, take the midpoints of the upper and lower feature line segments as feature points B. U With B D , respectively representing the maximum value point and the minimum value point along the y-axis in the bottom plane area A1 of the microstructure unit.

[0022] Preferably, the contact half-chord length of the grinding wheel is obtained according to the characteristic line segment, and the microstructure unit is divided into three areas: the bottom plane area A1, the cutting-in and cutting-out area A2, and the sidewall area A3, including:

[0023] In the structured grinding process, the profile of the raised part of the structured grinding wheel forms the cutting-in and cutting-out bevel area A2 when cutting in and out. When the raised part with a radius of R continuously reaches the maximum grinding depth, the bottom plane area A1 of the microstructure unit is formed. The side wall area A3 of the microstructure unit is formed by the radius R on the structured grinding wheel which changes according to the set rule. i formed by the edges.

[0024] Preferably, the contour of the top region of the structured grinding wheel with the largest radius is inversely solved based on the contour of the A1 region, including:

[0025] According to the selected contact half-chord length l c and the depth a of the microstructure unit p , the maximum radius R of the structured grinding wheel is obtained, which is expressed as:

[0026] R=(l c 2 +a p 2 ) / 2a p ;

[0027] Taking feature point B U With B D As the dividing point, the contour function g of the bottom plane area in the microstructure unit B The left and right parts of (x,y) are:

[0028]

[0029] Taking feature point B U With B D As the dividing point, the function of the left and right parts of the contour of the convex part is obtained, which is expressed as:

[0030]

[0031] Where ω is the angular velocity of the grinding wheel, v w is the feed speed of the workpiece, There are two feature points B D and B U The y-axis coordinate value of

[0032] All the formulas combined give:

[0033]

[0034] The area surrounded by the left and right functions is the top area of ​​the structured grinding wheel with a radius of R. The contour formed by the two functions is named C R .

[0035] Preferably, the equation of the corresponding edge on the structured grinding wheel is inversely solved according to the description function of the edge of A3, including:

[0036] Point L on the structured grinding wheel surface U 'With B U ' and L D 'With B D 'The contours of the curves in space,

[0037]

[0038] Among them, R i It is the radius of any point on the grinding wheel surface.

[0039] Preferably, the extreme points in the x and y directions on the structured grinding wheel are sequentially connected to form the remaining curved surfaces of the convex portion of the structured grinding wheel except for the top at the maximum radius, including:

[0040] For any x i , connect contour C along the y-axis H With contour C R , when connecting, you should use L L With L R The connecting line is the dividing line, that is, it cannot cross the C of the structured grinding wheel. R The area is connected, and the function of the projection of the curve on the yOz plane is f PUi (y,z) and f PDi (y,z), expressed as:

[0041]

[0042] Among them, h PU (y,z) and h PD (y,z) are h U (x,y,z) and h D Function of the projection of (x,y,z) onto the yOz plane.

[0043] The present invention also provides a structured grinding wheel design system for efficient grinding of structured array surfaces, the system being used to implement the aforementioned method, the system comprising: an analysis module, a parsing module, a partitioning module, a first inverse solution module, a first connection module, a second inverse solution module, a second connection module, and a detection module;

[0044] The analysis module is used to analyze the concavity and convexity and symmetry of the target microstructure unit profile, determine the feasibility of the structured grinding method, and perform appropriate simplification;

[0045] The analysis module is used to analyze the microstructure unit contour graphic to obtain the size, characteristic points and characteristic line segments of the microstructure unit contour graphic;

[0046] The division module is used to obtain the contact half-chord length of the grinding wheel according to the characteristic line segment, and divide the microstructure unit into three areas: the bottom plane area A1, the cutting-in and cutting-out area A2, and the sidewall area A3;

[0047] The first inverse solution module is used to inversely solve the contour of the top area of ​​the structured grinding wheel with the largest radius based on the contour of the A1 area;

[0048] The first connecting module is used to connect the midpoints of the contours of the microstructure units in the A3 area along the grinding direction to form the edges of the sidewall area A3 of the microstructure;

[0049] The second inverse solution module is used to inversely solve the equation of the corresponding edge on the structured grinding wheel according to the description function of the edge of A3;

[0050] The second connection module is used to sequentially connect the extreme points in the x and y directions on the structured grinding wheel to form the remaining curved surfaces of the convex part of the structured grinding wheel except the top at the largest radius, while ensuring that the abrasive on each curved surface only plays a supporting role and does not interact with the workpiece surface;

[0051] The detection module is used to manufacture several groups of corresponding structured grinding wheels according to different characteristic line segment selection schemes, use specific grinding parameters to conduct process tests, detect and evaluate the processing results of the microstructure array, and select the optimal group as the final design scheme of the structured grinding wheel.

[0052] Compared with the prior art, the present invention has the following beneficial effects:

[0053] 1. The structured grinding wheel design method proposed in the present invention is a goal-oriented design method. It is guided by the demand for large-area microstructure arrays in industry. The design parameters of the structured grinding wheel and the corresponding grinding process parameters are inversely solved according to the principles of grinding kinematics. This method can effectively ensure the correctness of the microstructure array obtained by the final processing, while avoiding the inefficiency of the current structured grinding operation of first making the structured grinding wheel and then processing the microstructure surface, and the error problem of being unable to achieve the target microstructure.

[0054] 2. This method has strong universality. It is not only applicable to microstructures with contours composed of simple straight lines, but also to microstructures with contours composed of complex curves. As long as the conditions for using this method are met, corresponding structured grinding wheels can be designed and processed through structured grinding.

[0055] 3. The design of the structured grinding wheel is directly related to the grinding process parameters. The process of designing the grinding wheel is also the process of optimizing the grinding process. By exploring and optimizing the process of feasible solutions, we can ultimately determine the design of a rational structured grinding wheel and the appropriate grinding process parameters. This will help extend the service life of the structured grinding wheel and further reduce the manufacturing cost of large-area microstructure arrays. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] In order to more clearly illustrate the technical solution of the present invention, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0057] Figure 1 Schematic diagram of the concavo-convexity of the microstructure profile pattern of an embodiment of the present invention, wherein (a) is a convex pattern in the x-direction; (b) is a concave pattern in the x-direction; (c) is decomposed into several convex patterns in the x-direction;

[0058] Figure 2 Schematic diagrams of the symmetry of the microstructure profile patterns of the embodiments of the present invention, wherein (a) is symmetric about the x-axis or the y-axis; (b) is symmetric about both the x-axis and the y-axis;

[0059] Figure 3 Schematic diagram of three characteristic regions of the microstructure formed by structured grinding according to an embodiment of the present invention;

[0060] Figure 4 Schematic diagram of the structured grinding wheel design process according to an embodiment of the present invention;

[0061] Figure 5 Schematic diagram of the distribution of the microstructure array along the grinding direction according to an embodiment of the present invention;

[0062] Figure 6 Schematic diagram of the projection of the raised portion of the structured grinding wheel on the yOz plane according to an embodiment of the present invention;

[0063] Figure 7 This is a flow chart of structured grinding wheel design according to an embodiment of the present invention;

[0064] Figure 8 The present invention is a schematic flow chart of a method for designing a structured grinding wheel for efficient grinding of a structured array surface according to an embodiment of the present invention. DETAILED DESCRIPTION

[0065] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0066] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0067] Example 1

[0068] Structured grinding is an effective method for efficiently fabricating microstructure arrays. Structured grinding wheels with a specific surface concave-convex pattern are essential tools for this process. Correct design directly impacts the ability to achieve the desired microstructure array. According to the principles of grinding kinematics, the concave-convex pattern on the surface of the structured grinding wheel maps to the target microstructure array. However, a systematic approach to designing a structured grinding wheel based on the target microstructure array is currently lacking. In the method proposed in the present invention, it is first necessary to analyze the characteristics of the target microstructure array to clarify the geometric parameters such as the shape, size, depth of the microstructure unit and the distribution density of the microstructure array; secondly, a geometric mapping model of the structured grinding wheel-microstructure array is established (the model refers to the mathematical relationship between the geometric parameters of the structured grinding wheel and the geometric parameters of the microstructure array under the conditions of grinding kinematics, where the geometric parameters of the structured grinding wheel include the grinding wheel radius R, the shape of the protruding part, the height change of the protruding part, etc., and the geometric parameters of the microstructure array include the contour shape, geometric dimensions of the microstructure unit, the distance between adjacent microstructure arrays, etc.), and the three types of parameters representing the microstructure array, the grinding process and the structured grinding wheel (parameters of the microstructure array: the contour shape, geometric dimensions of the microstructure unit, the distance between adjacent microstructure arrays, etc.; grinding process parameters: workpiece feed speed v w, grinding wheel rotation angular velocity ω; structured grinding wheel parameters: grinding wheel radius R, shape of the raised part, height change of the raised part, etc.) are all parametrically represented (parametric representation mainly refers to the parametric description of variables such as contour shape, shape of the raised part, height change of the raised part, etc. that vary according to the microstructure array and the structured grinding wheel, that is, they are described by functions. The relationship between the parametric representation process and the established geometric mapping model: it should be parametrically represented first, and then they are linked together through the grinding kinematics principle, specifically the subsequent equations); then according to the kinematic equation of structured grinding (the kinematic equation of grinding kinematics is an analytical expression that describes how, under specific grinding wheel geometric parameters and grinding process parameters, the motion trajectory of each abrasive particle interferes with the workpiece and forms a processed area on the workpiece surface during grinding, see formula (1). The traditional grinding kinematic equation is the process from grinding wheel geometric parameters + grinding parameters to workpiece surface morphology, and the inverse solution refers to the process from workpiece surface morphology + The process from grinding parameters to grinding wheel geometric parameters. The initial solution means that in this design method, the selection of characteristic line segments is not fixed, so it has countless possibilities, which will lead to the calculated structured grinding wheel design scheme and the combination of grinding process parameters are not fixed. Therefore, a sufficient number of characteristic line segments can be selected here, and a sufficient number of solutions can be solved by this method, that is, the combination of structured grinding wheel parameters and grinding process parameters. Subsequently, it is necessary to conduct preliminary screening based on the experience of processing equipment and grinding experts to remove difficult-to-implement solutions, and finally conduct process experiments to further optimize several groups of solutions), inversely solve the combination of structured grinding wheel parameters and grinding process parameters, and obtain a sufficient number of initial solutions; then, combined with the actual processing capabilities of the processing equipment and the engineering experience of grinding experts, discard unreasonable parameter combinations and determine several groups of feasible solutions that meet objective conditions (for example, if the calculated grinding wheel size is very small, it is not realistic to actually manufacture such a grinding wheel; or the actually required grinding process parameters, such as feed speed v w is particularly high, exceeding the maximum speed of the processing equipment. Objectively, this set of design solutions cannot be used); finally, several sets of structured grinding wheels are prepared according to the feasible solution (according to the design solution, the structured grinding wheel can be manufactured by additive manufacturing, laser processing, ion beam processing and precision mechanical dressing, etc.), and combined with the matching structured grinding process, structured grinding experiments are carried out to obtain several sets of corresponding microstructure arrays (the main content of this method is to design a structured grinding wheel, and the matching grinding process parameters, i.e., v w With ω, the structured grinding wheel manufactured according to the design scheme is installed on the grinding machine using this set of parameters, and the grinding depth, i.e. the microstructure depth a, is set. p, after adjusting the position and posture of the workpiece, the processing can be started. With the rotation of the structured grinding wheel and the feed of the workpiece, the target microstructure array can be directly formed on the surface of the workpiece due to the raised structure on the surface of the structured grinding wheel). By comparing and evaluating the processing effects of each group of microstructure arrays, the optimal parameter combination is determined, that is, the final solution is determined (for the results of the microstructure arrays obtained by processing according to different design schemes, it is necessary to characterize their contour accuracy and surface quality, which can be done specifically by instruments such as scanning electron microscopes and white light interferometers. Finally, the design scheme with the best contour accuracy of the microstructure array is selected as the final scheme to complete the design of the structured grinding wheel and the planning of the structured grinding process. The present invention provides a systematic structured grinding wheel design method for efficiently preparing microstructure arrays using a structured grinding method, which is of great significance for correctly, reasonably and efficiently realizing the processing of target microstructure arrays.

[0069] The equations of grinding kinematics are:

[0070]

[0071] Where R i is the radius of the i-th abrasive particle, t is the processing time, θ i is the angle between the i-th abrasive grain on the grinding wheel and the grinding starting point, x i is the x coordinate value of the i-th abrasive particle, y i is the y coordinate value of the i-th abrasive particle, z i is the z coordinate value of the i-th abrasive grain, where x is the grinding direction, y is the direction of the grinding wheel axis, and z is the normal direction of the workpiece surface.

[0072] like Figure 8 As shown, this embodiment provides a structured grinding wheel design method for efficient grinding of structured array surfaces, the method comprising:

[0073] Analyze the concavity and symmetry of the target microstructure unit contour to determine the feasibility of the structured grinding method and perform appropriate simplification. Specifically, by analyzing the concavity and convexity of the target microstructure unit, if the microstructure unit is convex along the grinding direction, the structured grinding method is feasible; otherwise, it is not feasible. By analyzing the symmetry of the target microstructure unit, if the target microstructure is symmetrical along the x-axis and the y-axis, it can be simplified along the symmetry axis. Only the smallest symmetric unit is inversely solved to obtain the design parameters of the convex part of the simplified structured grinding wheel. Finally, the obtained structured grinding wheel can be mirrored along the original symmetry axis.

[0074] Analyze the microstructure unit contour graphic to obtain the size, characteristic points and characteristic line segments of the microstructure unit contour graphic;

[0075] The contact half-chord length of the grinding wheel is obtained according to the characteristic line segment, and the microstructure unit is divided into three areas: the bottom plane area A1, the cutting-in and cutting-out area A2, and the side wall area A3;

[0076] According to the contour of area A1, the contour of the top area with the largest radius of the structured grinding wheel is inversely solved;

[0077] The midpoints of the contours of the microstructure units in the A3 area along the grinding direction are connected to form the edges of the sidewall area A3 of the microstructure;

[0078] According to the description function of the edge of A3, the equation of the corresponding edge on the structured grinding wheel is solved inversely;

[0079] The extreme points in the x and y directions on the structured grinding wheel are connected in sequence to form the remaining curved surfaces of the convex part of the structured grinding wheel except for the top at the largest radius. At the same time, it is ensured that the abrasive on each curved surface only plays a supporting role and does not interact with the workpiece surface.

[0080] Several groups of corresponding structured grinding wheels were manufactured according to different characteristic line segment selection schemes. Process tests were carried out using specific grinding parameters. The processing results of the microstructure array were tested and evaluated, and the optimal group was selected as the final design scheme of the structured grinding wheel.

[0081] The present invention is achieved through the following technical solutions:

[0082] First, some limitations of the target microstructure discussed in this invention are clarified (there are some requirements for the shape of the target microstructure. The method should ensure that it is convex along the x-direction when processing some microstructures, otherwise it may not be possible to process them according to this method). Along the grinding direction, that is, the x-direction, the outline of the microstructure unit should be topologically convex, that is, the line segment connecting any two points with equal y in the figure should be located in the figure, such as Figure 1 As shown in a). For the concave figure along the grinding direction, Figure 1 As shown in b), we will not consider it here, but in fact we can analyze it by decomposing the concave figure into several convex figures, such as Figure 1 As shown in c).

[0083] For a given target microstructure unit that meets the requirements, first analyze the symmetry of the outline of the microstructure unit. If the figure is only symmetrical about the x-axis or the y-axis, the outline of the microstructure unit can be simplified to 1 / 2 of the original figure about the symmetry axis, such as Figure 2 As shown in a); if the figure is symmetrical about the x-axis and the y-axis, the outline of the microstructure unit can be simplified to 1 / 4 of the original figure, as shown in Figure 2 As shown in b).

[0084] Secondly, it should be made clear that due to the kinematic characteristics of grinding, the microstructure produced by the structured grinding method has three characteristic regions, such as Figure 3 As shown, they are respectively the bottom plane area A1, the cutting-in and cutting-out bevel area A2, and the sidewall bevel area A3.

[0085] Determine the maximum and minimum points along the y-axis L U With L D , L U With L D The difference in the y-axis direction is Δy. If the extreme point in the y-axis direction is located on a line segment parallel to the x-axis, then the extreme point is not unique. The maximum point and the minimum point along the x-axis direction are L R With L L , their horizontal distance along the x direction is L x In addition, there may be several vertices P1, P2, ..., P in the outline graph of the microstructure unit. n , if the graph is a smooth curve, the number of vertices is 0.

[0086] Determine the characteristic line segment s randomly according to the following requirements f If the feature point L U With L D are all unique, and the characteristic line segment s f There should be two lines, one with a length of l along the x-axis. x Two line segments s fu and s fd , where l x is the length of the characteristic line segment, s fu and s fd Refers to two characteristic line segments. The selection of characteristic line segments is not fixed and can be within a certain range, so there is no expression. x The difference between the x values ​​of the left and right functions at the y value can be calculated. After the characteristic line segment is selected, its y-axis coordinate can be obtained. Substitute the y value into g L (x,y) and g R (x,y), solve for the corresponding x L with x R , then l x =x R -x L . l c is the contact half chord length, which should be 0.5l x , and the feature point L U and the characteristic line segment s below fd The distance between them is d U (0.5·Δy <d u <Δy), feature point L Dand the characteristic line segment s located above fu The distance between them is d D (0.5·Δy <d d <Δy). Make the lengths of the two characteristic line segments meet the conditions, l x =2·l c , where l c is the contact half chord length between the grinding wheel and the workpiece during grinding. U With L D If only one point is unique, then only one characteristic line segment that meets the requirements can be found. U With L D If the characteristics are not unique, then countless characteristic line segments that meet the requirements can be found. It is worth noting that in the process of determining the characteristic line segments, since their positions are randomly set, the contact half-chord length l c This is also equivalent to randomness, so there are countless options for selecting feature segments, which is also the main reason for the countless options for the subsequent structured grinding wheel design. Here, a sufficient number of options can be selected, such as 15 to 30 groups of options as the initial solution.

[0087] According to the selected contact half-chord length l c and the depth a of the microstructure unit p , the maximum radius R of the structured grinding wheel can be obtained according to the following formula (2):

[0088]

[0089] On the characteristic line segment s f After confirmation, continue to determine the feature points, and take the midpoints of the upper and lower feature line segments as feature points B. U With B D , which respectively represent the maximum value point and the minimum value point along the y-axis in the bottom plane area A1 of the microstructure unit. Figure 4 shown.

[0090] like Figure 5 As shown, the distance P between two adjacent microstructure units along the grinding direction can be obtained. Since the microstructure units should be separated from each other, there will actually be a relationship as shown in formula (3),

[0091] L x ≤P(3)

[0092] The distribution density of the microstructure array d d The maximum length L of the microstructure unit along the grinding direction x It is described by the ratio of the distance P between two adjacent microstructures, see formula (4),

[0093] dd =L x / P(4)

[0094] According to the distribution density d of the microstructure array d , P can be calculated by the following formula (5):

[0095] P=L x / d d ×100%(5)

[0096] According to the principle of grinding kinematics, P can also be calculated by the following formula (6):

[0097] P=2πR / n·ω·R / v w (6)

[0098] Where n is the number of raised units evenly distributed on the surface of the structured grinding wheel, ω is the angular velocity of the grinding wheel, and v w is the feed rate of the workpiece. Accordingly, the number n of the raised units on the surface of the structured grinding wheel and the grinding process parameters ω and v can be obtained from formula (6): w There is a certain relationship between them.

[0099] Then extract the contour curve function g(x,y) of the graph C of the microstructure unit. U With L D As the dividing point, the left and right contour curve functions of the microstructure unit are g L (x,y) and g R (x,y). Then the fd With s fu The left and right contours between g L (x,y) and g R (x,y) increases and decreases along the x direction respectively. c The length of the bottom plane area in the microstructure unit is obtained by B (x,y), with feature point B U With B D As the dividing point, the left and right parts of the function can be expressed by the following formula (7):

[0100]

[0101] In the process of forming the microstructure, the contour of the raised portion of the structured grinding wheel plays a decisive role in the bottom plane area and the cutting-in and cutting-out area of ​​the microstructure unit. In the structured grinding process, the contour of the raised portion of the structured grinding wheel forms the cutting-in and cutting-out inclined surface area A2 when cutting in and out. When the raised portion with a radius of R continuously reaches the maximum grinding depth, the bottom plane area A1 of the microstructure unit is formed. Therefore, the bottom plane area A1 of the microstructure unit and the cutting-in and cutting-out inclined surface area A2 jointly determine the form of the raised portion of the structured grinding wheel. According to the grinding kinematics relationship, the characteristic point B U With B D As the dividing point, the functions of the left and right parts of the contour of the convex part can be obtained, which is expressed by the following formula (8):

[0102]

[0103] Where ω is the angular velocity of the grinding wheel, v w is the feed speed of the workpiece. There are two feature points B D and B U The y-axis coordinate value of .

[0104] Combining formulas (2), (7) and (8), we can obtain formula (9):

[0105]

[0106] The area surrounded by the left and right functions is the top area of ​​the structured grinding wheel with a radius of R. The contour formed by the two functions is named C R .

[0107] At this point, according to the bottom plane area A1 of the microstructure unit and the cutting-in and cutting-out bevel area A2, the profile of the convex part of the structured grinding wheel surface can be determined, that is, The part with the largest radius of the structured grinding wheel has been clearly defined. The next task is to design the part of the structured grinding wheel that determines the side wall area A3 of the microstructure unit.

[0108] Structured grinding wheel with L U With L D The corresponding point L U 'With L D 'The radius value R i It should be exactly Ra p , to ensure that when the structured grinding wheel produces microstructure units, the corresponding point on the grinding wheel reaches the lowest point and keeps in contact with the workpiece surface, that is, the grinding depth of the point is equal to 0, that is, the contact half chord length l of the corresponding point of the grinding wheel c= 0. The sidewall area A3 of the microstructure unit is formed by the radius R of the structured grinding wheel which changes according to a certain rule. i The edge is formed by the edge, which should be a curve. Along the y-axis direction, the two end points L of the edge curve on the upper side of the structured grinding wheel are U 'With B U ' respectively correspond to L on the microstructure unit U With B U , similarly, the edge curve at the bottom, its two endpoints L D 'With B D ' respectively correspond to L on the microstructure unit D With B D For the microstructure unit from L U To B U The curves of L cannot be simply connected by straight lines, but should be calculated based on the contour graphic function of the microstructure unit. U To B U The curve, each point on the curve should satisfy the following conditions, for each The x of a point on the curve M It should be the x point (x L with x R ) can be calculated by the following formula (10):

[0109]

[0110] Among them, x R As parameters, after eliminating them, we get the equation g about x and y U (x,y) is the desired value from L U To B U Similarly, we can get the curve function from L below. D To B D The curve function, g D (x,y).

[0111] Similarly, according to the principles of grinding kinematics, point L on the surface of the structured grinding wheel U 'With B U ' and L D 'With B D The contour of the curve between ' in space is as follows (11):

[0112]

[0113] Among them, R i It is the radius of any point on the grinding wheel surface. It is called h U and h Dis a curve in space, because R i It changes in the direction perpendicular to the xOy plane, that is, the radial direction of the structured grinding wheel. If the circumferential surface of the grinding wheel is unfolded into a plane, it can be called the z direction. i It can be calculated by the following formula (12):

[0114]

[0115] Where H is the height from the grinding wheel rotation center to the workpiece surface, which can be calculated by the following formula (13):

[0116] H=Ra p (13)

[0117] l ci For as well as The contact half-chord length of the microstructure unit in the interval can be directly obtained from the graph of the microstructure unit. U (x,y) and g D (x,y) is in the same interval g L (x,y) and g R The set of midpoints of (x, y), hence the edge curve h of the structured grinding wheel surface U and h D The cutting-in and cutting-out process can directly form the sidewall area A3 of the microstructure unit.

[0118] L connecting the z=H surface of the structured grinding wheel U 'Dot and L L 'Point, L U 'Dot and L R 'Point, L D 'Dot and L L 'Point and L D 'Dot and L R 'Points, forming the contour C of the structured grinding wheel z=H surface H In order to ensure that the four curved surfaces (△L U 'B U 'L L ', △L U 'B U 'L R ', △L D 'B D 'L L ' and △L D 'B D 'L R The abrasive on the ') does not participate in the grinding process, but only plays a supporting role. There are certain requirements for the height variation function of these four surfaces. Specifically, Figure 6As shown, for any x i , connect contour C along the y-axis H With contour C R , when connecting, you should use L L With L R The connecting line is the dividing line, that is, it cannot cross the C of the structured grinding wheel. R The area is connected, and the function of the projection of the curve on the yOz plane is f PUi (y,z) and f PDi (y,z), they should satisfy the relationship of formula (14),

[0119]

[0120] Among them, h PU (y,z) and h PD (y,z) are h U (x,y,z) and h D The function of the projection of (x, y, z) on the yOz plane. In practice, the four surfaces can be kept as concave as possible to avoid interference with the target microstructure.

[0121] At this point, all the parameters of the structured grinding wheel have been designed, but it is worth noting that the calculation process involves the grinding wheel's rotational angular velocity ω and the workpiece's feed speed v w . Therefore, for different process parameters, the specific size of the concave and convex structure of the structured grinding wheel will change. After combining the actual processing capabilities of the processing equipment and the engineering experience of grinding experts, several groups of suitable process parameter combinations can be screened out, such as 5 to 9 groups, and each scheme is a feasible solution. Then the structured grinding wheel is manufactured according to the corresponding design scheme. As for the manufacture of structured grinding wheels, a laser processing method can be used to carve out several structured grinding wheels that meet the requirements according to the design scheme. And carry out structured grinding experiments according to the matching grinding process parameters, and then detect the morphology of the obtained microstructure array and the wear state of the structured grinding wheel, compare the experimental results, and comprehensively select the optimal scheme M with the best processing accuracy and the least grinding wheel wear. O , as the final design scheme of the structured grinding wheel and the combination of structured grinding parameters. The design process of the entire structured grinding wheel is summarized as the process Figure 7 .

[0122] Example 2

[0123] The present invention also provides a structured grinding wheel design system for efficient grinding of structured array surfaces, the system being used to implement the aforementioned method, the system comprising: an analysis module, a parsing module, a partitioning module, a first inverse solution module, a first connection module, a second inverse solution module, a second connection module, and a detection module;

[0124] Analysis module, used to analyze the concavity and convexity and symmetry of the target microstructure unit profile, determine the feasibility of the structured grinding method and make appropriate simplifications;

[0125] An analysis module is used to analyze the microstructure unit contour graphic and obtain the size, characteristic points and characteristic line segments of the microstructure unit contour graphic;

[0126] A division module is used to obtain the contact half-chord length of the grinding wheel according to the characteristic line segment, and divide the microstructure unit into three areas: the bottom plane area A1, the cutting-in and cutting-out area A2, and the side wall area A3;

[0127] The first inverse solution module is used to inversely solve the contour of the top area with the largest radius of the structured grinding wheel based on the contour of area A1;

[0128] A first connecting module is used to connect the midpoints of the contours of the microstructure units in the A3 area along the grinding direction to form the edges of the sidewall area A3 of the microstructure;

[0129] The second inverse solution module is used to inversely solve the equation of the corresponding edge on the structured grinding wheel according to the description function of the edge of A3;

[0130] The second connection module is used to sequentially connect the extreme points in the x and y directions on the structured grinding wheel to form the remaining curved surfaces of the convex part of the structured grinding wheel except the top at the largest radius, while ensuring that the abrasive on each curved surface only plays a supporting role and does not interact with the workpiece surface;

[0131] The detection module is used to manufacture several groups of corresponding structured grinding wheels according to different feature line segment selection schemes, conduct process tests using specific grinding parameters, detect and evaluate the processing results of the microstructure array, and select the optimal group as the final design scheme for the structured grinding wheel.

[0132] The embodiments described above are merely descriptions of preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Without departing from the spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by persons skilled in the art should fall within the scope of protection defined by the claims of the present invention.

Claims

1. A method for designing a structured grinding wheel for efficient grinding of structured array surfaces, characterized in that: The method comprises: Analyze the concavity and symmetry of the target microstructure unit contour, determine the feasibility of the structured grinding method and make appropriate simplifications; Analyze the microstructure unit contour graphic to obtain the size, characteristic points and characteristic line segments of the microstructure unit contour graphic; The contact half-chord length of the grinding wheel is obtained according to the characteristic line segment, and the microstructure unit is divided into three areas: the bottom plane area A1, the cutting-in and cutting-out area A2, and the side wall area A3; According to the contour of area A1, the contour of the top area with the largest radius of the structured grinding wheel is inversely solved; The midpoints of the contours of the microstructure units in the A3 area along the grinding direction are connected to form the edges of the sidewall area A3 of the microstructure; According to the description function of the edge of A3, the equation of the corresponding edge on the structured grinding wheel is solved inversely; The extreme points in the x and y directions on the structured grinding wheel are connected in sequence to form the remaining curved surfaces of the convex part of the structured grinding wheel except for the top at the largest radius. At the same time, it is ensured that the abrasive on each curved surface only plays a supporting role and does not interact with the workpiece surface. Several groups of corresponding structured grinding wheels were manufactured according to different characteristic line segment selection schemes. Process tests were carried out using specific grinding parameters. The processing results of the microstructure array were tested and evaluated, and the optimal group was selected as the final design scheme of the structured grinding wheel.

2. The method according to claim 1, characterized in that Analyze the concavity and convexity of the target microstructure unit contour, including: Along the grinding direction, i.e., the x-direction, the outline of the microstructure unit is topologically convex, that is, the line segment connecting any two points with equal y in the figure should be located within the figure. For figures that are concave along the grinding direction, the concave figure is analyzed by decomposing it into several convex figures. Analyze the concavity and symmetry of the target microstructure unit contour, including: If the figure is symmetrical only about the x-axis or the y-axis, the outline of the microstructure unit is simplified to 1 / 2 of the original figure about the symmetry axis; if the figure is symmetrical about both the x-axis and the y-axis, the outline of the microstructure unit is simplified to 1 / 4 of the original figure.

3. The method according to claim 2, characterized in that Analyze the microstructure unit contour graphic to obtain the size, feature points, and feature line segments of the microstructure unit contour graphic, including: Determine the maximum and minimum points along the y-axis L U With L D , L U With L D The difference in the y-axis direction is Δy; if the extreme point in the y-axis direction is located on a line segment parallel to the x-axis, then the extreme point is not unique; determine the maximum point and the minimum point along the x-axis direction L R With L L , L R With L L The horizontal distance along the x direction is L x ; There are several vertices P1, P2, ..., P in the outline of the microstructure unit. n , if the graph is a smooth curve, the number of vertices is 0; If the feature point L U With L D are all unique, and the characteristic line segment s f The length along the x-axis is l x Two line segments s fu and s fd , and the feature point L U and the characteristic line segment s below fd The distance between them is d U , where 0.5·Δy <d u <Δy, feature point L D and the characteristic line segment s located above fu The distance between them is d D , where 0.5·Δy <d d <Δy, so that the lengths of the two characteristic line segments meet the conditions, l x =2·l c , where l c is the contact half chord length between the grinding wheel and the workpiece during grinding; if at the characteristic point L U With L D In the equation, only one point is unique, then only one characteristic line segment that meets the requirements can be found. If two characteristic points L U With L D If they are not unique, then find countless characteristic line segments that meet the requirements; On the characteristic line segment s f After confirmation, take the midpoints of the upper and lower feature line segments as feature points B. U With B D , respectively representing the maximum value point and the minimum value point along the y-axis in the bottom plane area A1 of the microstructure unit.

4. The method according to claim 3, characterized in that The contact half-chord length of the grinding wheel is obtained according to the characteristic line segment, and the microstructure unit is divided into three areas: the bottom plane area A1, the cutting-in and cutting-out area A2, and the side wall area A3, including: In the structured grinding process, the profile of the raised part of the structured grinding wheel forms the cutting-in and cutting-out bevel area A2 when cutting in and out. When the raised part with a radius of R continuously reaches the maximum grinding depth, the bottom plane area A1 of the microstructure unit is formed. The side wall area A3 of the microstructure unit is formed by the radius R on the structured grinding wheel which changes according to the set rule. i formed by the edges.

5. The method according to claim 4, characterized in that According to the contour of area A1, the contour of the top area with the largest radius of the structured grinding wheel is inversely solved, including: According to the selected contact half-chord length l c and the depth a of the microstructure unit p , the maximum radius R of the structured grinding wheel is obtained, which is expressed as: R=(l c 2 +a p 2 ) / 2a p ; Taking feature point B U With B D As the dividing point, the contour function g of the bottom plane area in the microstructure unit B The left and right parts of (x,y) are: Taking feature point B U With B D As the dividing point, the function of the left and right parts of the contour of the convex part is obtained, which is expressed as: Where ω is the angular velocity of the grinding wheel, v w is the feed speed of the workpiece, There are two feature points B D and B U The y-axis coordinate value of All the formulas combined give: The area surrounded by the left and right functions is the top area of ​​the structured grinding wheel with a radius of R. The contour formed by the two functions is named C R .

6. The method according to claim 5, characterized in that According to the description function of the edge of A3, the equation of the corresponding edge on the structured grinding wheel is inversely solved, including: Point L on the structured grinding wheel surface U 'With B U ' and L D 'With B D 'The contours of the curves in space, Among them, R i It is the radius of any point on the grinding wheel surface.

7. The method according to claim 6, characterized in that The extreme points in the x and y directions on the structured grinding wheel are connected in sequence to form the remaining curved surfaces of the convex part of the structured grinding wheel except the top at the maximum radius, including: For any x i , connect contour C along the y-axis H With contour C R , when connecting, you should use L L With L R The connecting line is the dividing line, that is, it cannot cross the C of the structured grinding wheel. R The area is connected, and the function of the projection of the curve on the yOz plane is f PUi (y,z) and f PDi (y,z), expressed as: Among them, h PU (y,z) and h PD (y,z) are h U (x,y,z) and h D Function of the projection of (x,y,z) onto the yOz plane.

8. A structured grinding wheel design system for efficient grinding of structured array surfaces, the system being used to implement the method according to any one of claims 1 to 7, characterized in that: The system includes: an analysis module, a parsing module, a division module, a first inverse solution module, a first connection module, a second inverse solution module, a second connection module, and a detection module; The analysis module is used to analyze the concavity and convexity and symmetry of the target microstructure unit profile, determine the feasibility of the structured grinding method, and perform appropriate simplification; The analysis module is used to analyze the microstructure unit contour graphic to obtain the size, characteristic points and characteristic line segments of the microstructure unit contour graphic; The division module is used to obtain the contact half-chord length of the grinding wheel according to the characteristic line segment, and divide the microstructure unit into three areas: the bottom plane area A1, the cutting-in and cutting-out area A2, and the sidewall area A3; The first inverse solution module is used to inversely solve the contour of the top area of ​​the structured grinding wheel with the largest radius based on the contour of the A1 area; The first connecting module is used to connect the midpoints of the contours of the microstructure units in the A3 area along the grinding direction to form the edges of the sidewall area A3 of the microstructure; The second inverse solution module is used to inversely solve the equation of the corresponding edge on the structured grinding wheel according to the description function of the edge of A3; The second connection module is used to sequentially connect the extreme points in the x and y directions on the structured grinding wheel to form the remaining curved surfaces of the convex part of the structured grinding wheel except the top at the largest radius, while ensuring that the abrasive on each curved surface only plays a supporting role and does not interact with the workpiece surface; The detection module is used to manufacture several groups of corresponding structured grinding wheels according to different characteristic line segment selection schemes, use specific grinding parameters to conduct process tests, detect and evaluate the processing results of the microstructure array, and select the optimal group as the final design scheme of the structured grinding wheel.

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