用有限元法设计金刚石砂轮电解修整的阴极

根据电解成形理论设计阴极,用于金属结合剂成形金刚石砂轮的电解修整。应用有限元法求解电场中的拉普拉斯方程几何反问题,计算出阴极曲线形状。假定初始阴极形状,施加阳极边界条件,从砂轮阳极表面开始逐层计算电位分布,求得修整间隙区域的等电位线,从而得到修整阴极工具曲线族。通过设计阴极与砂轮廓形的对比,分析了成形砂轮轮廓形状,修整电压和电解液电导率对设计阴极形状的影响。研究结果表明:设计阴极与成形砂轮的廓形并不一致。随着成形砂轮廓形曲率,修整电压和电导率的增加,设计阴极与砂轮廓形的偏差加大。为了修整出精确的砂轮廓形,成形砂轮的修整参数应保持稳定。

Cathode Design with FEM for Profile Diamond Wheel Dressing

The cathode tool shapes , engaged in electrolytic dressing of metal-bonded diamond wheels, were designed based on electrolytic machining theory. The finite element method was applied to solve the inverse boundary problem of Laplace's equation in electric field, and cathode curve was calculated. By assuming initial cathode shape and applying boundary conditions to anode, potential in dressing gap was computed layer by layer from the beginning of wheel surface. Then equi-potential lines were calculated. Finally, cluster of cathode tool curves was obtained. Comparing design cathode with wheel profile shape, effects of dressing parameters, wheel profile, dressing voltage and conductance on design cathode profile were studied. The calculated results show that design cathode is different from wheel profile, deviation between cathode and wheel profile increases with dressing voltage, curvatures of wheel profile and conductance. To obtain precise wheel profile, the dressing parameters should keep steady during the dressing operations.