响应曲面法优化超声振动辅助ELID复合内圆磨削ZTA陶瓷的边界损伤长度

本文基于响应曲面法的Box-Behnken设计方法,开展超声振动辅助在线电解修整(ELID)复合内圆(UAEI)磨削氧化锆增韧氧化铝(ZTA)陶瓷试验,建立响应面模型;结合显著性检验、试验得到的响应曲面和等高线图,研究ELID电源电压、磨削深度、轴向进给量和砂轮转速四个工艺参数及其交互作用对边界损伤长度的影响规律;以最小边界损伤长度为优化目标,得到UAEI磨削ZTA陶瓷的最优参数组合为:EILD电源电压86.39 V,磨削深度为1.55 μm,轴向进给量为81.24 mm/min,砂轮转速为2 741.41 r/min,得到最优边界损伤长度理论预测值Ltv为6.537 μm。经过试验检验,相对误差在合理范围内,所建立的响应面模型具有较高精度,为UAEI磨削加工工艺参数的合理选择提供一定的参考。

Optimization of Boundary Damage Length in Ultrasonic Vibration Assisted Electrolytic in-Process Dressing Internal Grinding of ZTA Ceramics by Response Surface Methodology

Experiment of ultrasonic vibration assisted electrolytic in-process dressing internal (UAEI) grinding for zirconia toughened alumina (ZTA) ceramics was carried out based on Box-Behnken design method of response surface methodology, and response surface model was established. The influence law of four process parameters of electrolytic in-process dressing (ELID) power supply voltage, grinding depth, axial feed and wheel speed and their interaction on the boundary damage length was studied through significance test, response surface plot and contour map obtained from experiments. The influence intensity of significant factors on response value was obtained by analyzing the response surface plot and contour map obtained from response surface model, and the cause of the interaction influence on response value was also analyzed. The influence intensity of significant factors on response value in descending order are grinding depth, ELID power supply voltage, axial feed and wheel speed. The influence intensity of interaction of factors combination on the response value in descending order are interaction between grinding depth and grinding wheel speed, interaction between axial feed and grinding wheel speed, interaction between ELID power supply voltage and grinding depth, interaction between grinding depth and axial feed. Taking the minimum boundary damage length as the optimization objective, the optimal combination of parameters of UAEI grinding for ZTA ceramics are as follows: ELID power supply voltage is 86.39 V, grinding depth is 1.55 μm, axial feed is 81.24 mm/min, wheel speed is 2 741.41 r/min, and the theoretical prediction value of optimal boundary damage length is 6.537 μm. The relative error is within a reasonable range by experimental verification. The response surface model has a higher precision and provides some reference for reasonable selection of process parameters of UAEI grinding.