基于磨粒行为的珩磨材料去除机理研究
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摘要
珩磨是一种材料去除加工工艺，被广泛应用于发动机缸体、压缩机、阀体、轴承、液压缸等耦合件的加工。经珩磨加工的工件表面具有良好的抗磨性能，由于珩磨加工产生的交叉网纹可用于存储润滑油并可作为润滑油路，从而达到润滑减磨的作用。
珩磨加工通常是一件产品的最终加工工序，其加工痕迹将直接保留在最终工件表面上。因此，被加工表面纹理特性与产品磨损性能直接受到加工参数以及材料去除机理的影响。所以，珩磨加工材料去除机理的研究，对优化加工工艺参数、改善表面网纹结构、提高工件抗磨性等具有重要意义。然而目前珩磨材料去除机理的研究较少，尤其缺乏对材料去除过程的微观分析。
本文将基于珩磨加工中的磨粒行为特性，开展加工中材料去除机理的研究。文中对该加工过程的微观分析主要将从以下方面展开：油石表面磨粒研究、珩磨加工中的有效磨粒分析、单磨粒动态材料去除机理分析。
文章建立了油石表面形貌模拟模型，分析了油石表面磨粒分布；建立了“油石-工件”接触模型来识别加工中参与材料去除的有效磨粒；建立了三维有限元分析模型（FEA）来分析单磨粒切削下的材料去除过程，并分析加工中的残余应力情况；建立了数学模型用于预测加工参数对材料去除量以及珩磨圆周加工精度的影响；最后通过实验对部分模型预测结果进行了验证，并分析了珩磨加工中的磨削力与油石磨损。
珩磨加工材料去除机理的研究成果，不仅对改善珩磨加工效率、优化珩磨参数、提高工件性能等具有重要意义，同时对研磨、端面磨削等固结磨粒面接触磨削形式均具有指导意义。
Honing is a material removal process widely used in manufacturing of matingparts such as engine cylinders, compressors, valves, bearings, and hydraulic cylinders.The surface topography generated by honing has a profound effect on the tribologicalperformance of the honed surface since the cross-hatch pattern on the workpiece surfacecan be used to retain oil or grease to ensure proper lubrication and minimize wear.
Honing as finishing operation reflects the mechanics of material removal duringthe process depending on the process parameters used. Therefore, it is important tostudy the material removal during the process, so that the machining parameters can beoptimally selected to enhance the tribological performance by improve the cross-hatchpattern on the workpiece. Thus there still is a lack of knowledge on the mechanicalmicroscopic analysis of the material removal mechanism.
This thesis presents a study of material removal in honing by grain behavior. Thismicroscopic analysis of this process consists in studying of the abrasive grains on thetool surface, effective grains during the honing process, material removal mechanism bysingle grain and grain dynamics.
The grains on the tool surface are studied by a tool topography model; effectivegrains are obtained by a physics-based model on tool-workpiece interaction; materialremoval process by single grain is demonstrated through a3D finite element model; theeffect of grain dynamics on material removal is studied by a mathematic model. Finally,the models proposed in this thesis and the predicted results by these models are verifiedby pilot experiments. Other parameters, for example honing force and tool wear, arealso discussed through experiments.
The results in this thesis can also be used to study more general abrasive process(as abrasive wear) and has led to a better understanding of plastic deformations andfailure local mechanisms encountered in this process.
珩磨加工通常是一件产品的最终加工工序，其加工痕迹将直接保留在最终工件表面上。因此，被加工表面纹理特性与产品磨损性能直接受到加工参数以及材料去除机理的影响。所以，珩磨加工材料去除机理的研究，对优化加工工艺参数、改善表面网纹结构、提高工件抗磨性等具有重要意义。然而目前珩磨材料去除机理的研究较少，尤其缺乏对材料去除过程的微观分析。
本文将基于珩磨加工中的磨粒行为特性，开展加工中材料去除机理的研究。文中对该加工过程的微观分析主要将从以下方面展开：油石表面磨粒研究、珩磨加工中的有效磨粒分析、单磨粒动态材料去除机理分析。
文章建立了油石表面形貌模拟模型，分析了油石表面磨粒分布；建立了“油石-工件”接触模型来识别加工中参与材料去除的有效磨粒；建立了三维有限元分析模型（FEA）来分析单磨粒切削下的材料去除过程，并分析加工中的残余应力情况；建立了数学模型用于预测加工参数对材料去除量以及珩磨圆周加工精度的影响；最后通过实验对部分模型预测结果进行了验证，并分析了珩磨加工中的磨削力与油石磨损。
珩磨加工材料去除机理的研究成果，不仅对改善珩磨加工效率、优化珩磨参数、提高工件性能等具有重要意义，同时对研磨、端面磨削等固结磨粒面接触磨削形式均具有指导意义。
Honing is a material removal process widely used in manufacturing of matingparts such as engine cylinders, compressors, valves, bearings, and hydraulic cylinders.The surface topography generated by honing has a profound effect on the tribologicalperformance of the honed surface since the cross-hatch pattern on the workpiece surfacecan be used to retain oil or grease to ensure proper lubrication and minimize wear.
Honing as finishing operation reflects the mechanics of material removal duringthe process depending on the process parameters used. Therefore, it is important tostudy the material removal during the process, so that the machining parameters can beoptimally selected to enhance the tribological performance by improve the cross-hatchpattern on the workpiece. Thus there still is a lack of knowledge on the mechanicalmicroscopic analysis of the material removal mechanism.
This thesis presents a study of material removal in honing by grain behavior. Thismicroscopic analysis of this process consists in studying of the abrasive grains on thetool surface, effective grains during the honing process, material removal mechanism bysingle grain and grain dynamics.
The grains on the tool surface are studied by a tool topography model; effectivegrains are obtained by a physics-based model on tool-workpiece interaction; materialremoval process by single grain is demonstrated through a3D finite element model; theeffect of grain dynamics on material removal is studied by a mathematic model. Finally,the models proposed in this thesis and the predicted results by these models are verifiedby pilot experiments. Other parameters, for example honing force and tool wear, arealso discussed through experiments.
The results in this thesis can also be used to study more general abrasive process(as abrasive wear) and has led to a better understanding of plastic deformations andfailure local mechanisms encountered in this process.
引文
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Baseri, H.S.; Rezaei, M.; Rahimi, A.; Saadat, M.(2008) Analysis of the disc dressingeffects on grinding performance, part1: simulation of the disc dressed wheelsurface, Machining Science and Technology,12:183-196.
Beyer, P.; van Ravenzwaaij, M.(2005) Innovative flat honing with vitrified-bondgrinding and conditioning tools. Industrial Diamond Review,65(4):47-50.
Borkowski, J. A.; Szymański, A. M.(1992) Uses of abrasives and abrasive tools. EllisHorwood, New York, USA.
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Brinksmeler, E.; Glwerzew, A.(2003) Chip formation mechanisms in grinding at lowspeeds, CIRP Annals-Manufacturing Technology,52:253-258.
Brumgard, J.W.(1993) Fundamentals of honing fluids. SME Technical Paper (Series)MR,1-12.
Butler, D. L.; Blunt, L. A.; See, B.K.; Webster, J.A.; Stout, K.J.(2002) Characterizationof grinding wheels using3D surface measurement techniques, Journal of MaterialsProcessing Technology,127(2):234-237.
Cai, R.; Rowe, W.B.(2004) Assessment of vitrified CBN wheels for precision grinding.International Journal of Machine Tools and Manufacture,44(12-13):1391-1402.
Chen, X.; Rowe, W.B.(1996) Analysis and simulation of the grinding process. Part I.Generation of the grinding wheel surface. International Journal of Machine Toolsand Manufacture,36(8):871-882.
Chen, D.; Feng, Q.(2009) A methodology for the simulation of surface-contact grindingtool topography, Key Engineering Materials,416:348-353.
Chepovetskii, I.Kh.; Barabolya, A.V.(1986a) Cutting forces and temperatures inantifriction plateau honing. Soviet Journal of Superhard Materials (Englishtranslation of Sverkhtverdye Materialy),8(1):67-71.
Chepovetskii, I.Kh.; Yushchenko, S.A.(1986b) Selection of diamond honing methodusing the minimum workpiece wear during the running-in period as a criterion.Soviet Journal of Superhard Materials (English translation of SverkhtverdyeMaterialy),8(2):54-60.
Chepovetskii, I.Kh.; Barabolya, A.V.; Pavliskii, V.M.(1986c) Increasing thetribotechnical properties of cylinder sleeves in honing. Soviet journal of superhardmaterials,8(6):66-71.
Chepovetskii, I.Kh.; Barabolya, A.V.; Pavliskii, V.M.; Ogorodnik, V.V.; Ivas'kevich,Ya.V.(1987) Tribotechnical properties of internal-combustion-engine cylindersleeves, finished by the flat-top antifriction honing method. Soviet Journal ofFriction and Wear (English translation of Trenie i Iznos),8(1):138-140.
Collins J.A.(1981) Failure of materials in mechanical design. John Wiley&Sons, NewYork, USA, p591.
Cristea, R.; Neagu, C.; Dumitrescu, A.; Bayer, M.(1998) Machinability functions incast-iron honing with diamond tools. UPB Scientific Bulletin, Series D MechanicalEngineering,60(3):381-388.
De Pellegrin, D.V.; Stachowiak, G.W.(2004) Evaluating the role of particle distributionand shape in two-body abrasion by statistical simulation, Tribology International,37:255-270.
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