磨粒切厚可控的脆性材料延性域磨削基础研究
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摘要
制约脆性材料高效精密磨削技术进一步发展的主要瓶颈是脆性材料不能以完全延性的方式进行加工，材料加工后会出现一定数量的表面和亚表面缺陷，从而影响了脆性材料产品的使用性能和可靠性。以往的解决办法是采用超细粒度的砂轮、或者采用高速磨削工艺等措施，这些虽然为脆性材料的加工提供了解决方案，但并未从根本上解决脆性材料如何实现既高效又延性加工的问题。
常用砂轮的磨粒是随机分布的，每颗磨粒的切厚是无法控制的，所以总有很多磨粒处于脆性加工的状态，导致加工后的材料表面亚表面出现很多缺陷。由此本文构想采用粗粒度的单层钎焊金刚石砂轮，通过磨粒的有序排布控制磨粒间距，通过对磨粒的精密修整控制磨粒的等高性，再通过磨削工艺参数的调整来实现磨粒切厚及其一致性的控制，如果所有的磨粒切厚都能控制在脆性材料延脆域转变的临界切厚值以下，那么脆性材料的延性加工就可以实现。这样即使普通的磨床设备和磨削工艺也能实现较大去除率的脆性材料延性加工，因此可以实现脆性材料的高效精密加工。围绕此构想，本文主要完成了以下研究工作：
（1）采用树脂金刚石砂轮对铁氧体材料进行了磨削实验，考察了铁氧体材料表面粗糙度随磨削工艺参数的变化规律以及磨削铁氧体的表面特征，观察了树脂金刚石砂轮的表面形貌在磨损过程中的变化，最后加工铁氧体零件成品。通过磨削实验证明，由于砂轮磨粒是无序排布、磨粒把持强度低、磨粒等高性差且没有微刃性，难以准确控制磨粒切厚及其一致性，所以磨削的表面粗糙度难以改善。据此可推断较高磨粒把持强度的砂轮如果磨粒满足有序排布、等高性和微刃性，则可以准确控制磨粒切厚及其一致性，实现脆性材料的延性域磨削。
（2）理论分析了粗粒度砂轮难以实现延性域磨削的原因，考察了普通砂轮磨粒切厚的特征及其统计分布形态，提出了磨粒切厚的控制措施，最后制作出了能控制磨粒切厚及其一致性和砂轮基体高温变形的磨粒有序排布钎焊金刚石砂轮。
（3）提出了采用杯形树脂金刚石砂轮修整钎焊金刚石砂轮的方法，搭建了修整装置。提出了改进的软钢修整方法。对两种修整工艺进行了研究，考察了砂轮形貌和磨粒等高性在修整过程中的变化。待钎焊金刚石砂轮修整好后对各种脆性材料的磨削工艺进行了研究。实验证明，两项修整工艺技术改善了钎焊金刚石砂轮磨粒的等高性。脆性材料的磨削表面质量有所提高。
（4）通过改进的钎焊工艺和修整工艺实现了氧化锆陶瓷的延性域磨削。改进的钎焊工艺抑制了砂轮侧壁表面钎料的过度流淌和金刚石磨粒的包埋，使得磨粒高度在砂轮宽度方向上更加均匀，磨粒有较大的出露，改进修整工艺使得砂轮磨粒在修整的过程中实现有限的破碎，既保证了磨粒的等高性又保证了磨粒的微刃性，最终磨削氧化锆陶瓷的表面粗糙度可以达到Ra0.1μm以下，该表面磨削纹理连续细密，材料去除基本上属于延性域的模式。
The bottleneck of the further development of high efficiency precision grinding of brittle materialsis the difficulty of achieving the complete ductile machining of them, which will induce some surfaceand subsurface defects and influence the service performance and reliability of the brittle materialproducts. The traditional method to solve is to use superfine grinding wheel, or to introduce highspeed grinding. These methods are some kinds of solvent. But they can not solve the problem of notonly high efficiency but also ductile machining.
The position of grains in the traditional grinding wheel surface is stochastic, which can not controlthe depth of cut of individual grain. Accordingly, many grains are in the mode of brittle machining,which can induce many defects in the surface and subsurface of the ground material.The dissertationconceives to use monolayer brazed diamond grinding wheel of large grit size, controlling theinter-grain space by means of orderly distributed grains, controlling the height uniformity of grains bymeans of precision dressing of the grains, and basically controlling the single grain cutting depth bymeans of regulating the process parameters, If single grain cutting depth is controlled under thecritical depth of cut which determines the transition from brittle mode to ductile mode for brittlematerial machining, then the ductile machining of brittle material is realized. The ductile machiningof brittle material with large removal rate can be achieved although traditional grinder and process areused. Consequently, the high efficiency precision process of brittle material is realized. For the sake ofthis, the paper has completed some following research work:
(1)The experiment of ferrite material grinding with resin bonded diamond grinding wheel wascarried out. The surface roughness variation and the surface microscopic feature of ferrite withgrinding process parameter has been observed. The grinding wheel topography variation with wear isobserved. At last complicated shaped ferrite part has been manufactured. The grinding experimentproves that because of the random distribution of grains, lower grain retention, no grain heightuniformity and no grain micro-edges with respect to normal grinding wheel, the undeformed chipthickness and its uniformity can not be controlled accurately, which determines the ground surfacequality cannot be improved easily. Accordingly, it is speculated that grinding wheel with higer grainretention, orderly distributed grains, grain height uniformity and grain micro-edges will controlundeformed chip thickness accurately and realize ductile regime grinding.
(2)The difficulty of ductile regime grinding with large grit size grinding wheel is analyzedtheoretically. The feature and statistical distribution of undeformed chip thickness are observed. Themethods of controlling undeformed chip thickness are proposed. At last the grinding wheel withorderly distributed grains has been developed, which address the problem of high temperaturedeformation of wheel matrix and controlling of undeformed chip thickness and its uniformity.
(3)The dressing method of brazed diamond grinding wheel with cup shaped resin bonded grindingwheel is proposed. The experiment rig is equipped. The improved mild steel dressing method isproposed. The two dressing processes are studied. The grinding wheel topography and grain heightuniformity during dressing process are observed. After that various brittle material grinding process isstudied. The results show that the two dressing process improved the diamond grain height uniformity greatly and the ground surface quality of brittle materials has been increased greatly.
(4)With the improved brazing process and the improved dressing process, the ductile regimegrinding is realized. The improved brazing process controls the overflow of brazing alloy fluid on alateral surface and the over-embedment of diamond grains, which makes grain height uniformity inthe direction of grinding wheel width more even and makes grain protrusion larger. With theimproved dressing process, the grinding wheel grains can achieve limited fracture, which not untilensure the grit height uniformity but also ensure the micro edges of grains. At last the ground surfaceroughness of zirconia achieves Ra0.1μm, of which the surface grinding texture is very consecutiveand dense, and the material removal is generally in the ductile regime.
常用砂轮的磨粒是随机分布的，每颗磨粒的切厚是无法控制的，所以总有很多磨粒处于脆性加工的状态，导致加工后的材料表面亚表面出现很多缺陷。由此本文构想采用粗粒度的单层钎焊金刚石砂轮，通过磨粒的有序排布控制磨粒间距，通过对磨粒的精密修整控制磨粒的等高性，再通过磨削工艺参数的调整来实现磨粒切厚及其一致性的控制，如果所有的磨粒切厚都能控制在脆性材料延脆域转变的临界切厚值以下，那么脆性材料的延性加工就可以实现。这样即使普通的磨床设备和磨削工艺也能实现较大去除率的脆性材料延性加工，因此可以实现脆性材料的高效精密加工。围绕此构想，本文主要完成了以下研究工作：
（1）采用树脂金刚石砂轮对铁氧体材料进行了磨削实验，考察了铁氧体材料表面粗糙度随磨削工艺参数的变化规律以及磨削铁氧体的表面特征，观察了树脂金刚石砂轮的表面形貌在磨损过程中的变化，最后加工铁氧体零件成品。通过磨削实验证明，由于砂轮磨粒是无序排布、磨粒把持强度低、磨粒等高性差且没有微刃性，难以准确控制磨粒切厚及其一致性，所以磨削的表面粗糙度难以改善。据此可推断较高磨粒把持强度的砂轮如果磨粒满足有序排布、等高性和微刃性，则可以准确控制磨粒切厚及其一致性，实现脆性材料的延性域磨削。
（2）理论分析了粗粒度砂轮难以实现延性域磨削的原因，考察了普通砂轮磨粒切厚的特征及其统计分布形态，提出了磨粒切厚的控制措施，最后制作出了能控制磨粒切厚及其一致性和砂轮基体高温变形的磨粒有序排布钎焊金刚石砂轮。
（3）提出了采用杯形树脂金刚石砂轮修整钎焊金刚石砂轮的方法，搭建了修整装置。提出了改进的软钢修整方法。对两种修整工艺进行了研究，考察了砂轮形貌和磨粒等高性在修整过程中的变化。待钎焊金刚石砂轮修整好后对各种脆性材料的磨削工艺进行了研究。实验证明，两项修整工艺技术改善了钎焊金刚石砂轮磨粒的等高性。脆性材料的磨削表面质量有所提高。
（4）通过改进的钎焊工艺和修整工艺实现了氧化锆陶瓷的延性域磨削。改进的钎焊工艺抑制了砂轮侧壁表面钎料的过度流淌和金刚石磨粒的包埋，使得磨粒高度在砂轮宽度方向上更加均匀，磨粒有较大的出露，改进修整工艺使得砂轮磨粒在修整的过程中实现有限的破碎，既保证了磨粒的等高性又保证了磨粒的微刃性，最终磨削氧化锆陶瓷的表面粗糙度可以达到Ra0.1μm以下，该表面磨削纹理连续细密，材料去除基本上属于延性域的模式。
The bottleneck of the further development of high efficiency precision grinding of brittle materialsis the difficulty of achieving the complete ductile machining of them, which will induce some surfaceand subsurface defects and influence the service performance and reliability of the brittle materialproducts. The traditional method to solve is to use superfine grinding wheel, or to introduce highspeed grinding. These methods are some kinds of solvent. But they can not solve the problem of notonly high efficiency but also ductile machining.
The position of grains in the traditional grinding wheel surface is stochastic, which can not controlthe depth of cut of individual grain. Accordingly, many grains are in the mode of brittle machining,which can induce many defects in the surface and subsurface of the ground material.The dissertationconceives to use monolayer brazed diamond grinding wheel of large grit size, controlling theinter-grain space by means of orderly distributed grains, controlling the height uniformity of grains bymeans of precision dressing of the grains, and basically controlling the single grain cutting depth bymeans of regulating the process parameters, If single grain cutting depth is controlled under thecritical depth of cut which determines the transition from brittle mode to ductile mode for brittlematerial machining, then the ductile machining of brittle material is realized. The ductile machiningof brittle material with large removal rate can be achieved although traditional grinder and process areused. Consequently, the high efficiency precision process of brittle material is realized. For the sake ofthis, the paper has completed some following research work:
(1)The experiment of ferrite material grinding with resin bonded diamond grinding wheel wascarried out. The surface roughness variation and the surface microscopic feature of ferrite withgrinding process parameter has been observed. The grinding wheel topography variation with wear isobserved. At last complicated shaped ferrite part has been manufactured. The grinding experimentproves that because of the random distribution of grains, lower grain retention, no grain heightuniformity and no grain micro-edges with respect to normal grinding wheel, the undeformed chipthickness and its uniformity can not be controlled accurately, which determines the ground surfacequality cannot be improved easily. Accordingly, it is speculated that grinding wheel with higer grainretention, orderly distributed grains, grain height uniformity and grain micro-edges will controlundeformed chip thickness accurately and realize ductile regime grinding.
(2)The difficulty of ductile regime grinding with large grit size grinding wheel is analyzedtheoretically. The feature and statistical distribution of undeformed chip thickness are observed. Themethods of controlling undeformed chip thickness are proposed. At last the grinding wheel withorderly distributed grains has been developed, which address the problem of high temperaturedeformation of wheel matrix and controlling of undeformed chip thickness and its uniformity.
(3)The dressing method of brazed diamond grinding wheel with cup shaped resin bonded grindingwheel is proposed. The experiment rig is equipped. The improved mild steel dressing method isproposed. The two dressing processes are studied. The grinding wheel topography and grain heightuniformity during dressing process are observed. After that various brittle material grinding process isstudied. The results show that the two dressing process improved the diamond grain height uniformity greatly and the ground surface quality of brittle materials has been increased greatly.
(4)With the improved brazing process and the improved dressing process, the ductile regimegrinding is realized. The improved brazing process controls the overflow of brazing alloy fluid on alateral surface and the over-embedment of diamond grains, which makes grain height uniformity inthe direction of grinding wheel width more even and makes grain protrusion larger. With theimproved dressing process, the grinding wheel grains can achieve limited fracture, which not untilensure the grit height uniformity but also ensure the micro edges of grains. At last the ground surfaceroughness of zirconia achieves Ra0.1μm, of which the surface grinding texture is very consecutiveand dense, and the material removal is generally in the ductile regime.
引文
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