钛合金干式磨抛加工技术研究
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摘要
钛合金具有比强度高、耐热性和耐蚀性好等优良性能,在许多工业领域特别是航空航天领域得到越来越广泛的应用。同时,钛合金的热导率低、弹性模量小、化学活性高,易导致工件磨抛表面烧伤和砂轮磨损,钛合金干式磨抛加工作为钛合金大型结构件内外型面的终加工工序对零件表面质量有着决定性的影响。因此开展高锋利度静电植砂砂带、超硬磨料砂轮干式磨抛钛合金加工技术以及固体润滑技术研究,将有助于改善钛合金干式磨抛加工性能,提高钛合金零件表面质量、提升钛合金加工水平,并促进钛合金磨抛工具的开发及应用。
本文完成的主要研究工作包括:
(1)研制了一套砂带干式磨抛加工试验系统。采用夹丝热电偶测温方法对砂带干式磨抛钛合金工件表面温度进行了测量,研究了磨抛条件与工件表层温度、磨抛力和表面完整性等之间的关系,分析了锆刚玉砂带磨抛钛合金的磨粒磨损特征。设计开发了一套可控制加工用量的页轮/砂轮磨抛加工试验系统。研究了带柄页轮干式磨抛钛合金的工件表层温度、材料去除量、页轮磨损以及加工表面完整性等情况。设计了石墨固体润滑剂在磨粒表面的制备工艺,成功制备了石墨涂附带柄页轮,并分析了石墨含量与带柄页轮工件表层温度和表面粗糙度之间的关系。研究了钹形页轮恒力干式磨抛钛合金的表面粗糙度和材料去除量的变化情况。
(2)为提高砂轮回转精度,设计了砂轮柄与砂轮体组合式磨抛砂轮,通过控制磨粒的尺寸大小、磨粒的等高性和出露高度等,成功制备了新型单层钎焊立方氮化硼(CBN)砂轮,砂轮表面磨粒有序排布,磨粒具有良好的等高性和较大的出露高度。完成了干式磨抛钛合金试验研究。成功制备了石墨固体润滑剂涂附单层CBN砂轮,并分析了石墨含量与单层CBN砂轮工件表层温度和表面粗糙度的关系。
(3)提出了自润滑多层钎焊砂轮的概念,即在多层钎焊砂轮基体内加入固体润滑剂来改善其加工性能。阐明了多层钎焊砂轮自润滑机理,综合液相烧结与钎焊的工艺优势成功制备了自润滑多层钎焊金刚石和CBN砂轮。砂轮强度满足使用要求,金刚石砂轮空隙结构分布均匀,CBN砂轮中的石墨呈游离态均匀分布。完成了多层钎焊超硬磨料砂轮和碳化硅砂轮干式磨抛钛合金的加工性能及表面完整性对比研究。
(4)针对大型钛合金结构型面和平面结构的磨抛要求,优化选择了磨抛工具和磨抛用量,并完成了干式磨抛验证试验及结果分析。结果表明:工件表面质量达到了零件加工要求。
Titanium alloys have more and more applications in many industrial fields especially in aeronautics and astronautics in virtue of their high specific strength, good corrosion resistance and high thermal stability. However, titanium alloys are well known as a kind of difficult to machine material, due to its low thermal conductivity, small elastic module, and high chemical activity. Dry grinding and polishing as the key process of lager structure workpiece of titanium alloys has the decisive influence to the components surface quality. Because of the tools performance and the grinding parameters significantly influence the cost, efficiency and surface integrity, it is significant to develop the innovative belt, cubic boron nitride (CBN) abrasives grinding wheel at the same tine to evaluate the performance of grinding tools with solid lubricants were add into tools improve its machining grindability and ground surface quality for titanium alloys.
The main contents in this paper are as follows:
(1)The equipment was developed to employ belt in the grinding and polishing of titanium alloys. Grinding temperature was measured by a constantan-workpiece thermal couple. The influences of different parameters on grinding force and temperature by belt dry grinding are studied. This could provide a theoretical basis for the feasibility of machining titanium alloys with belt. The effects of grinding parameters and belt wear status on the surface integrity were investigated. The paper develops the equipment employs flap wheel in the grinding and polishing of titanium alloys, the equipment was to simulate flap wheel hand-held machining to study the grinding ability of flap wheel. The influence of different parameters on machining ability, flap wear, and grinding temperature were studied with flap wheel by dry grinding. Graphite is chosen to prepare the solid lubricant with the binder. Solid lubricant technology has been studied with the grinding flap wheels coated by solid lubricant. Comparative experiments with grinding flap wheels in different solid lubricant parameters were conducted. And the influence of different parameters on grinding temperature and surface roughness were studied.
(2)The innovative monolayer brazed cubic boron nitride (CBN) grinding wheels with rhythmed grain distribution were designed and fabricated accronding to the requirements of brazing technique to reliaze the grinding and polishing of titanium alloys. Moreover, on the basis of determined the suitable brazing process, the machining process of the grinding wheel with structural components mainly controlling the rotary accuracy of the wheel and the equal height characteristics of grains was effectively controlled, this kind of ordered-grained CBN grinding wheels which has been applied ground applied to titanium alloys was successfully developed. The grinding performance has been evaluated in the dry grinding process of the titanium alloys. Comparative experiments with grinding CBN wheels in different machining parameters were conducted. And the influence of different parameters on grinding temperature, wheel wear and surface intergrity were studied. The CBN grinding wheels with solid lubricant were prepared successfully. Meanwhile, the grinding temperature and the ground surface of the solid lubricant tools were evaluated.
(3)The innovative thought of the grinding wheel and increasing solid lubricant was proposed in order to reduce the intensity of heat source, and thus two new grinding wheels are developed and their performance of dry grinding titanium alloys were evaluated. Multi-layer brazing diamond and CBN grinding wheel were prepared successfully. The strength of grinding wheel meets the application requirements, the gap structure of diamond grinding wheel was well distributed, the graphite of CBN grinding wheel was evenly distributed in the free state, brazing achieved between binder and abrasive. The effects of grinding parameters status on the machining ablity and surface integrity were investigated on dry grinding by super abrasive grinding wheels and SiC wheel.
(4) According to the actual processing requirements, the representative lager structural components of titanium alloys was ground and polished with the combination optimization process to verify the result. Finally, the good surface quality was obtained.
本文完成的主要研究工作包括:
(1)研制了一套砂带干式磨抛加工试验系统。采用夹丝热电偶测温方法对砂带干式磨抛钛合金工件表面温度进行了测量,研究了磨抛条件与工件表层温度、磨抛力和表面完整性等之间的关系,分析了锆刚玉砂带磨抛钛合金的磨粒磨损特征。设计开发了一套可控制加工用量的页轮/砂轮磨抛加工试验系统。研究了带柄页轮干式磨抛钛合金的工件表层温度、材料去除量、页轮磨损以及加工表面完整性等情况。设计了石墨固体润滑剂在磨粒表面的制备工艺,成功制备了石墨涂附带柄页轮,并分析了石墨含量与带柄页轮工件表层温度和表面粗糙度之间的关系。研究了钹形页轮恒力干式磨抛钛合金的表面粗糙度和材料去除量的变化情况。
(2)为提高砂轮回转精度,设计了砂轮柄与砂轮体组合式磨抛砂轮,通过控制磨粒的尺寸大小、磨粒的等高性和出露高度等,成功制备了新型单层钎焊立方氮化硼(CBN)砂轮,砂轮表面磨粒有序排布,磨粒具有良好的等高性和较大的出露高度。完成了干式磨抛钛合金试验研究。成功制备了石墨固体润滑剂涂附单层CBN砂轮,并分析了石墨含量与单层CBN砂轮工件表层温度和表面粗糙度的关系。
(3)提出了自润滑多层钎焊砂轮的概念,即在多层钎焊砂轮基体内加入固体润滑剂来改善其加工性能。阐明了多层钎焊砂轮自润滑机理,综合液相烧结与钎焊的工艺优势成功制备了自润滑多层钎焊金刚石和CBN砂轮。砂轮强度满足使用要求,金刚石砂轮空隙结构分布均匀,CBN砂轮中的石墨呈游离态均匀分布。完成了多层钎焊超硬磨料砂轮和碳化硅砂轮干式磨抛钛合金的加工性能及表面完整性对比研究。
(4)针对大型钛合金结构型面和平面结构的磨抛要求,优化选择了磨抛工具和磨抛用量,并完成了干式磨抛验证试验及结果分析。结果表明:工件表面质量达到了零件加工要求。
Titanium alloys have more and more applications in many industrial fields especially in aeronautics and astronautics in virtue of their high specific strength, good corrosion resistance and high thermal stability. However, titanium alloys are well known as a kind of difficult to machine material, due to its low thermal conductivity, small elastic module, and high chemical activity. Dry grinding and polishing as the key process of lager structure workpiece of titanium alloys has the decisive influence to the components surface quality. Because of the tools performance and the grinding parameters significantly influence the cost, efficiency and surface integrity, it is significant to develop the innovative belt, cubic boron nitride (CBN) abrasives grinding wheel at the same tine to evaluate the performance of grinding tools with solid lubricants were add into tools improve its machining grindability and ground surface quality for titanium alloys.
The main contents in this paper are as follows:
(1)The equipment was developed to employ belt in the grinding and polishing of titanium alloys. Grinding temperature was measured by a constantan-workpiece thermal couple. The influences of different parameters on grinding force and temperature by belt dry grinding are studied. This could provide a theoretical basis for the feasibility of machining titanium alloys with belt. The effects of grinding parameters and belt wear status on the surface integrity were investigated. The paper develops the equipment employs flap wheel in the grinding and polishing of titanium alloys, the equipment was to simulate flap wheel hand-held machining to study the grinding ability of flap wheel. The influence of different parameters on machining ability, flap wear, and grinding temperature were studied with flap wheel by dry grinding. Graphite is chosen to prepare the solid lubricant with the binder. Solid lubricant technology has been studied with the grinding flap wheels coated by solid lubricant. Comparative experiments with grinding flap wheels in different solid lubricant parameters were conducted. And the influence of different parameters on grinding temperature and surface roughness were studied.
(2)The innovative monolayer brazed cubic boron nitride (CBN) grinding wheels with rhythmed grain distribution were designed and fabricated accronding to the requirements of brazing technique to reliaze the grinding and polishing of titanium alloys. Moreover, on the basis of determined the suitable brazing process, the machining process of the grinding wheel with structural components mainly controlling the rotary accuracy of the wheel and the equal height characteristics of grains was effectively controlled, this kind of ordered-grained CBN grinding wheels which has been applied ground applied to titanium alloys was successfully developed. The grinding performance has been evaluated in the dry grinding process of the titanium alloys. Comparative experiments with grinding CBN wheels in different machining parameters were conducted. And the influence of different parameters on grinding temperature, wheel wear and surface intergrity were studied. The CBN grinding wheels with solid lubricant were prepared successfully. Meanwhile, the grinding temperature and the ground surface of the solid lubricant tools were evaluated.
(3)The innovative thought of the grinding wheel and increasing solid lubricant was proposed in order to reduce the intensity of heat source, and thus two new grinding wheels are developed and their performance of dry grinding titanium alloys were evaluated. Multi-layer brazing diamond and CBN grinding wheel were prepared successfully. The strength of grinding wheel meets the application requirements, the gap structure of diamond grinding wheel was well distributed, the graphite of CBN grinding wheel was evenly distributed in the free state, brazing achieved between binder and abrasive. The effects of grinding parameters status on the machining ablity and surface integrity were investigated on dry grinding by super abrasive grinding wheels and SiC wheel.
(4) According to the actual processing requirements, the representative lager structural components of titanium alloys was ground and polished with the combination optimization process to verify the result. Finally, the good surface quality was obtained.
引文
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