Simulation to Microtopography Formation of CBN Active Abrasives on a Honing Wheel Surface

Abstract

The microtopography of a honing wheel surface composed of active abrasive grains is the key factor affecting the honing characteristics, and control of it is a sufficient condition to realize high-efficiency precision honing. Based on the magnetron sputtering method and phase field method, a theoretical model of cubic boron nitride (CBN) coating formation on a honing wheel surface is established. The physical vapor deposition (PVD) discrete phase field equation is solved by the finite difference method. A MATLAB program is compiled to simulate the formation process and micromorphology of the CBN coating on the honing wheel surface. A Taguchi method is designed to study the relationships of the sputtering time, substrate temperature, gas flow rate, and reaction space with the number of active abrasives and the length, width, height, and size of the abrasives. The simulation results are highly similar to the scanning electron microscopy (SEM) examinations, which shows that the model can accurately and effectively simulate the abrasive morphology of the wheel surface under different process conditions and provide a theoretical basis for the prediction and control of the CBN wear morphology on a honing wheel surface.

Quality evaluation of effective abrasive micro-edge honing based on Tra-FAH and SPA

“…In view of this problem, based on the basic meshing theory of internal honing [29], the micro-geometry of tooth surface [30][31], honing mechanism [32] and the finite element simulation model of multi-abrasive micro-edge honing, a multi-abrasive micro-edge honing characteristic evaluation model based on Trapeziform Fuzzy Analytic Hierarchy Process (Tra-FAHP) and Set Pair Analysis (SPA) is constructed by combining subjective and objective methods. The weight of evaluation index is determined by Tra-FAHP, the fuzziness of evaluation grade boundary of multi-abrasive micro-edge honing characteristics is considered by SPA membership function, and the internal relationship among CBN honing wheel, process parameters, workpiece precision and efficiency is established by qualitative and quantitative comprehensive evaluation method, which comprehensively and truly reflects the advantages and disadvantages of machining quality and provides decision-making basis for manufacturing high-performance hard gear.…”

Modeling of Specific Energy in the Gear Honing Process

“…Therefore, it is typically used as the final gear finishing process to improve the sound characteristics and lifespans of hardened gears. The performance of gear honing is typically evaluated by honing force [1], surface roughness after honing [3], the geometry of abrasive grains [4,5], and the fracture of abrasive grains [6]. However, none of these parameters can quantitatively measure the honing efficiency in the honing wheel and workpiece gear interaction process.…”