Prediction of Abrasive Belt Wear Based on BP Neural Network

Abrasive belt grinding is the key technology in high-end precision manufacturing field, but the working condition of abrasive particles on the surface of the belt will directly affect the quality and efficiency during processing. Aiming at the problem of the inability to monitor the wearing status of abrasive belt in real-time during the grinding process, and the challenge of time-consuming control while shutdown for detection, this paper proposes a method for predicating the wear of abrasive belt while the grinding process based on back-propagation (BP) neural network. First, experiments are carried out based on ultra-depth-of-field detection technology, and different parameter combinations are used to measure the degree of abrasive belt wear. Then the effects of different grinding speeds, different contact pressures, and different work piece materials on the abrasive belt wear rate are obtained. It can be concluded that the abrasive belt wear rate gradually increases as the grinding speed of the abrasive belt increases. With the increase of steel grade, the hardness of the steel structure increases, which intensifies the abrasive belt wear. As the contact pressure increases, the pressure on a single abrasive particle increases, which ultimately leads to increased wear. With the increase of contact pressure, the increase of the wear rate of materials with higher hardness is greater. By utilizing the artificial intelligence BP neural network method, 18 sets of experiment data are used for training BP neural network while 9 sets of data are used for verification, and the nonlinear mapping relationship between various process parameter combinations such as grinding speed, contact pressure, workpiece material, and wear rate is established to predict the wear degree of abrasive belt. Finally, the results of verification by examples show that the method proposed in this paper can fulfill the purpose of quickly and accurately predicting the degree of abrasive belt wear, which can be used for guiding the manufacturing processing, and greatly improving the processing efficiency.

Grinding Force and Heat of Titanium Alloy Abrasive Belt and Its Effect on Surface Integrity

Key rotating parts such as integral blisks and blades of aero-engines are widely made of titanium alloys. Abrasive belt grinding is one of the effective methods to improve the surface integrity. However, the grinding process produces greater grinding force and higher Grinding temperature,which have an impact on surface quality. At present, the force-heat coupling relationship in the grinding process and its influence on surface quality have not been explored. In this paper, a titanium alloy belt experiment is carried out to detect the force and temperature in the grinding process, this paper explores the influence of the grinding process parameters on the grinding force and temperature, and analyzes the influence on surface integrity of the force and temperature in the grinding process. The results show that the decrease of the belt linear speed, the increase of the feed speed and the grinding depth leads to the increase of the grinding force, the decrease of the feed speed, the increase of the belt linear speed and the grinding depth cause the temperature to rise. The effect of grinding depth on grinding force and grinding temperature is the most significant. And High grinding force and grinding temperature will cause the surface quality to deteriorate and even more serious defects. However, when the maximum temperature of the grinding temperature field reaches above 120°C, the surface roughness of the workpiece decreases from 1.596μm to 1.093μm, and the height of the surface undulation is reduced from 32μm to 19μm. This paper provides a reference for improving the surface integrity of the grinding process.

Contact Model And Simulation Analysis of Rail Grinding With Open-Structured Abrasive Belt Based On Pressing Plate

Recently, the emerging rail grinding method with open-structured abrasive belt based on pressing plate which adopts full contour copying grinding method to extend the working length of abrasive belt and is more suitable for preventative grinding and maintenance of rail corrugation in high-speed railway has been proposed. The essence of its grinding process is the complex nonlinear interaction among the pressing plate, abrasive belt and rail. The research on the contact mechanism of the rail grinding method with open-structured abrasive belt based on pressing plate is still very lacking, which limits the practical application of the emering rail grinding method to a certain extent. In this paper, a theoretical model of the contact between pressing plate, abrasive belt and rail is established. The contact area morphology and contact stress distribution were obtained, and validity of the theoretical model was verified by finite element simulation. At the same time, the distribution characteristics of contact stress under single concentrated force, uniform force and multiple concentrated force were studied based on the contact model. It is concluded that the multiple concentrated force is the optimal loading method, and the contact stress is more uniform, which is more conducive to repair the standard contour of rail.