PVA基粘弹性磁性磨具的实验研究及加工参数优化
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摘要
目的检验新研制的PVA基粘弹性磁性磨具的表面光整加工性能,掌握配比参数、加工条件等因素对加工效果的影响规律,并对加工参数进行优化以达到最佳加工效果。方法以6061铝合金管外圆表面为光整加工实验对象,通过先导实验首先确定出影响加工效果的主要因素及其参数范围,而后基于响应曲面法实验,对主轴转速、两相质量比、磨粒尺寸及加工时长等因素与工件表面粗糙度下降率(%?Ra)之间的关系进行了探究分析。结果最后通过对实验结果进行方差分析,建立了PVA基粘弹性磁性磨具加工铝合金管外表面的%?Ra预测模型,并对影响参数进行了优化设计,得到在最佳实验条件下(加工时间46 min、两相质量比1.45、主轴转速635r/min、磨粒尺寸65目),工件表面粗糙度下降率为92.5%,最低表面粗糙度为59 nm,显著改善了加工效果。结论作为一种新型光整加工介质PVA基粘弹性磁性磨具,其具有良好的自适应性及流动性,能达到较好的光整加工效果。影响%?Ra的单因素显著性从强到弱依次为:加工时长、主轴转速、磨粒尺寸、两相质量比。交互作用显著的因子为两相质量比+主轴转速、加工时长+主轴转速、两相质量比+磨粒尺寸。在主轴转速、加工时长取高水平,两相质量比取中等水平,磨粒尺寸取低或高水平时,能得到较好的表面加工效果。
The work aims to test the surface finishing performance of the newly developed PVA-based viscoelastic, mag-netic and abrasive tool, master the influence laws of the ratio parameters and processing conditions on the processing effect, andoptimize the processing parameters to achieve the best processing effect. The main factors affecting the machining effect and theparameters range were determined by the pilot experiment with the outer surface of 6061 aluminum alloy tube as the experi-mental object. Then, based on the response surface methodology(RSM), the relationship among the spindle speed, the mass ra-tio of two phases, the size of abrasive grains and the processing time and the reduction rate in surface roughness(%?Ra) wasexplored and analyzed. Finally, the %?Ra prediction model of PVA-based viscoelastic, magnetic and abrasive tool for aluminumalloy tube surface was established by variance analysis of experimental results, and the influence parameters were optimized.Under the optimum experimental conditions(processing time of 46 min, two-phase mass ratio of 1.45, spindle speed of 635 r/min and abrasive size of 65 mesh), the reduction rate of surface roughness of the workpiece reached 92.5%, and the best sur-face finish reached 59 nm, thus significantly improving the machining effects. As a new finishing medium, PVA-based viscoe-lastic, magnetic and abrasive tools have good adaptability and fluidity, and can achieve good finishing effect. The significantsingle factor affecting %?Ra from strong to weak is the processing time, spindle speed, abrasive particle size and two-phasemass ratio. The significant interactive factors are two-phase mass ratio+spindle speed, processing time + spindle speed andtwo-phase mass ratio+abrasive particle size. When the spindle speed and machining time are high, the mass ratio of two phasesis middle and the abrasive grain size is low or high, a better surface finishing effect can be obtained.
The work aims to test the surface finishing performance of the newly developed PVA-based viscoelastic, mag-netic and abrasive tool, master the influence laws of the ratio parameters and processing conditions on the processing effect, andoptimize the processing parameters to achieve the best processing effect. The main factors affecting the machining effect and theparameters range were determined by the pilot experiment with the outer surface of 6061 aluminum alloy tube as the experi-mental object. Then, based on the response surface methodology(RSM), the relationship among the spindle speed, the mass ra-tio of two phases, the size of abrasive grains and the processing time and the reduction rate in surface roughness(%?Ra) wasexplored and analyzed. Finally, the %?Ra prediction model of PVA-based viscoelastic, magnetic and abrasive tool for aluminumalloy tube surface was established by variance analysis of experimental results, and the influence parameters were optimized.Under the optimum experimental conditions(processing time of 46 min, two-phase mass ratio of 1.45, spindle speed of 635 r/min and abrasive size of 65 mesh), the reduction rate of surface roughness of the workpiece reached 92.5%, and the best sur-face finish reached 59 nm, thus significantly improving the machining effects. As a new finishing medium, PVA-based viscoe-lastic, magnetic and abrasive tools have good adaptability and fluidity, and can achieve good finishing effect. The significantsingle factor affecting %?Ra from strong to weak is the processing time, spindle speed, abrasive particle size and two-phasemass ratio. The significant interactive factors are two-phase mass ratio+spindle speed, processing time + spindle speed andtwo-phase mass ratio+abrasive particle size. When the spindle speed and machining time are high, the mass ratio of two phasesis middle and the abrasive grain size is low or high, a better surface finishing effect can be obtained.
引文
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[15]杨小朋,李秀红,李文辉,等.一种新型粘弹性磁性磨具的制备及其加工实验研究[J].机械设计与制造,2017(6):97-100.YANG Xiao-peng,LI Xiu-hong,LI Wen-hui,et al.The preparation of a new viscoelastic magnetic abrasive tool and finishing experiment research[J].Machinery design&manufacture,2017(6):97-100.
[16]王栋梁,李秀红,李文辉,等.以107硅橡胶为基体的粘弹性磁性磨具制备及实验研究[J].表面技术,2018,47(6):258-264.WANG Dong-liang,LI Xiu-hong,LI Wen-hui,et al.Preparation of viscoelastic magnetic abrasive tool based on 107 silicone rubber and experimental study[J].Surface technology,2018,47(6):258-264.
[17]SANKAR M R,JAIN V K,RAMKUMAR J,et al.Rheological characterization of styrene-butadiene based medium and its finishing performance using rotational abrasive flow finishing process[J].International journal of machine tools&manufacture,2011,51(12):947-957.
[18]KHERADMAND S,ESMAILIAN M,FATAHY A.Anovel approach of magnetorheological abrasive fluid finishing with swirling-assisted inlet flow[J].Results in physics,2016,6:568-580.
[19]LI Wen-hui,LI Xiu-hong,YANG Sheng-qiang,et al.Anewly developed media for magnetic abrasive finishing process:Material removal behavior and finishing performance[J].Journal of materials processing technology,2018,260:20-29.
[2]VIGNESH N K,SHANBHAG V V,BALASHANMUGAMN,et al.Ultra-precision finishing by magnetic abrasive finishing process[J].Materials today proceedings,2018,5(5):12426-12436.
[3]YAMAGUCHI H,SHINMURA T.Internal finishing process for alumina ceramic components by a magnetic field assisted finishing process[J].Precision engineering,2004,28(2):135-142.
[4]NTEZIYAREMYE V,WANG Y,LI W,et al.Surface finishing of needles for high-performance biopsy[J].Procedia cirp,2014,14:48-53.
[5]WANG Y,HU D.Study on the inner surface finishing of tubing by magnetic abrasive finishing[J].International journal of machine tools&manufacture,2005,45(1):43-49.
[6]YIN S,SHINMURA T.A comparative study:polishing characteristics and its mechanisms of three vibration modes in vibration-assisted magnetic abrasive polishing[J].International journal of machine tools&manufacture,2004,44(4):383-390.
[7]ZOU Y,XIE H,DONG C,et al.Study on complex micro surface finishing of alumina ceramic by the magnetic abrasive finishing process using alternating magnetic field[J].International journal of advanced manufacturing technology,2018,97:2193-2202.
[8]YOON S,TU J F,LEE J H,et al.Effect of the magnetic pole arrangement on the surface roughness of STS 304 by magnetic abrasive machining[J].International journal of precision engineering&manufacturing,2014,15(7):1275-1281.
[9]JUDAL K B,YADAVA V.Electrochemical magnetic abrasive machining of AISI304 stainless steel tubes[J].International journal of precision engineering&manufacturing,2013,14(1):37-43.
[10]李秀红.基于磁场特性的内孔表面光整新技术理论分析与实验研究[D].太原:太原理工大学,2010.LI Xiu-hong.Theoretical analysis and experimental study on hole surface finishing new technology based on magnetic field characteristics[D].Taiyuan:Taiyuan University of Technology,2010.
[11]高小龙,郑勇,孙帆,等.磁性磨料制备技术的研究进展[J].硬质合金,2010,27(2):118-123.GAO Xiao-long,ZHENG Yong,SUN Fan,et al.Research progress of preparation technique of magnetic abrasive grain[J].Cemented carbide,2010,27(2):118-123.
[12]黄虎,陈红玲,李文辉,等.粘弹性磁性磨料光整机理研究与加工实验[J].磁性材料及器件,2014,45(3):59-63.HUANG Hu,CHEN Hong-ling,LI Wen-hui,et al.Experiments and research on finishing mechanism of viscoelastic-magnetic abrasive[J].Journal of magnetic materials and devices,2014,45(3):59-63.
[13]翟洪飞,杨胜强,李文辉,等.粘弹性磁性磨具对铝板平面的光整加工研究[J].机械设计与制造,2012(7):133-135.ZHAI Hong-fei,YANG Sheng-qiang,LI Wen-hui,et al.Study of aluminum plane finishing by viscoelasticity magnetic abrasives[J].Machinery design&manufacture,2012(7):133-135.
[14]郭晓东,杨胜强,李文辉,等.粘弹性磁性磨具最佳加工时间的理论及实验研究[J].磁性材料及器件,2015(5):47-50.GUO Xiao-dong,YANG Sheng-qiang,LI Wen-hui,et al.Theoretical and experimental research on the optimum processing time of viscoelastic magnetic abrasive[J].Journal of magnetic materials and devices,2015(5):47-50.
[15]杨小朋,李秀红,李文辉,等.一种新型粘弹性磁性磨具的制备及其加工实验研究[J].机械设计与制造,2017(6):97-100.YANG Xiao-peng,LI Xiu-hong,LI Wen-hui,et al.The preparation of a new viscoelastic magnetic abrasive tool and finishing experiment research[J].Machinery design&manufacture,2017(6):97-100.
[16]王栋梁,李秀红,李文辉,等.以107硅橡胶为基体的粘弹性磁性磨具制备及实验研究[J].表面技术,2018,47(6):258-264.WANG Dong-liang,LI Xiu-hong,LI Wen-hui,et al.Preparation of viscoelastic magnetic abrasive tool based on 107 silicone rubber and experimental study[J].Surface technology,2018,47(6):258-264.
[17]SANKAR M R,JAIN V K,RAMKUMAR J,et al.Rheological characterization of styrene-butadiene based medium and its finishing performance using rotational abrasive flow finishing process[J].International journal of machine tools&manufacture,2011,51(12):947-957.
[18]KHERADMAND S,ESMAILIAN M,FATAHY A.Anovel approach of magnetorheological abrasive fluid finishing with swirling-assisted inlet flow[J].Results in physics,2016,6:568-580.
[19]LI Wen-hui,LI Xiu-hong,YANG Sheng-qiang,et al.Anewly developed media for magnetic abrasive finishing process:Material removal behavior and finishing performance[J].Journal of materials processing technology,2018,260:20-29.