Research on Rapid Prototyping Mechanism of Zerodur Grinding Surface Based on Multi-Parameter Coupling

The high-efficiency precision grinding of Zerodur still faces challenges in improving the material removal rate while ensuring the surface quality. In this study, the forming mechanism of glass-ceramic grinding surface under the coupling of multiple process parameters was systematically explored through theoretical modeling and experimental verification. Based on the assumption of rigid conical abrasive particles, a theoretical model of surface roughness (Ra) and material removal rate (MRR) was established. The influence of grinding wheel particle size, normal pressure and feed speed on Ra and MRR was revealed and verified by orthogonal experiments. The results show that the grinding wheel particle size has the most significant effect on Ra, and the use of 1000 # grinding wheel can reduce Ra by about 66 percent compared with 600 # grinding wheel. MRR increases significantly with the increase of grinding wheel particle size and normal pressure, but the surface quality decreases. The feed rate and feed speed have little effect on Ra, but can effectively improve MRR; increasing the rotational grinding wheel speed can improve the surface roughness to a certain extent, but the improvement effect on MRR is limited. Studies have confirmed that by optimizing the combination of grinding wheel particle size, normal pressure and motion parameters, high-efficiency grinding of Zerodur can be achieved under the condition of ensuring surface quality.