Collaborative control of surface quality and stability in hemispherical resonator grinding

During the grinding of hemispherical resonator and other hard-brittle complex curved components, variations in geometric features lead to changes in contact conditions and force states, inducing non-uniform wheel wear and resulting in fluctuations in workpiece surface quality. Previous studies have indicated that grinding parameters are key factors influencing surface integrity and wheel wear behavior in the machining of hard-brittle materials. Building on this understanding, an optimization strategy centered on the grinding ratio is proposed herein for the first time to achieve simultaneous improvement of workpiece surface quality and wheel lifespan. Initially, a correlation model between grinding parameters and the grinding ratio was established using multiple linear regression and analysis of variance, revealing the evolution of wheel wear behavior and workpiece surface integrity under different grinding ratio conditions. Furthermore, a multi-objective optimization model tailored for hemispherical resonator was formulated, and the non-dominated sorting genetic algorithm (NSGA-II) combined with the ideal distance method was employed to determine the optimal grinding parameters. Experimental results demonstrate that, following optimization, hemispherical resonator surface roughness can be maintained within 68.90–76.94 nm, representing an improvement of 21.62 %–37.05 % compared with conventional grinding parameters, while the fluctuation range decreased by 33.14 %. Moreover, under the same material removal volume, wheel wear was reduced by 16.07 %–35.14 %. The proposed grinding ratio–centered optimization framework provides a theoretical basis for achieving high-quality and stable machining of hard-brittle complex curved components while extending wheel lifespan.