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An equivalent-sphere-based grinding of large aspheric and spherical surfaces

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Abstract

This study investigated a novel methodology called equivalent-sphere swing grinding (ESSG) for the cup wheel grinding of large revolving aspheric and spherical surfaces. The method is proposed to improve the machining efficiency and reduce the complexity of machine tools. Different from the traditional single-point grinding of aspheric surfaces, the ESSG method developed a novel multipoint grinding process to increase the material removal rate (MRR) and reduce the wear of single abrasive grain. A structure with few axes and a wheel spindle with multi degrees of freedom simplifies the machine tools and improves the machine dynamic stiffness. The grinding process was modeled, and the feasibility for grinding aspheric and spherical surfaces was verified. The criteria for ESSG-based grinding method were established, and the wheel position and posture models were derived. The cup wheel posture was proved to have multiple options for grinding a revolving surface, in which the optimal posture can achieve the maximum number of abrasive particles involved in grinding and maximize MRR under the same wheel wear. The numerical trajectory control parameters were calculated, and a hierarchical grinding method is proposed. An experiment was conducted on a developed grinding machine prototype. The results indicate that the proposed methodology can efficiently grind paraboloid surfaces and can be extended to grinding other revolving aspheric and spherical surfaces.

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Funding

This study was funded by the National Natural Science Foundation of China (No. 52075331).

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Authors and Affiliations

  1. School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Liming Xu, Dejin Hu, Wenyou Dong, Chaolong Xie & Mengqi Liu

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  1. Liming Xu
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  2. Dejin Hu
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  3. Wenyou Dong
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  4. Chaolong Xie
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  5. Mengqi Liu
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Correspondence to Liming Xu.

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Xu, L., Hu, D., Dong, W. et al. An equivalent-sphere-based grinding of large aspheric and spherical surfaces. Int J Adv Manuf Technol 120, 1663–1676 (2022). https://doi.org/10.1007/s00170-022-08795-z

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  • DOI: https://doi.org/10.1007/s00170-022-08795-z

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