行星滚筒滚磨加工中液固两相湍流运动机理的计算和实验研究
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摘要
做为一种高效率的金属表面光整加工方法,离心式自由磨粒研磨工艺及设备在小型异形零件的去毛刺和光整加工生产领域得到广泛应用。该工艺的加工机理属于流体力学中液固两相湍流流动的理论范畴。长期以来,针对自由磨粒研磨技术的研究仅限于工艺实验,对研磨过程的本质特征尚无根本性的认识。目前离心式自由磨粒研磨设备的设计参数及研磨工艺参数完全凭经验确定,无理论依据。离心自由研磨过程中,受液固两相湍流流场的作用,磨料运动的流态特征对工件的加工质量和生产效率有明显影响。而研磨机行星传动比将直接改变湍流流场的分布,是影响整团磨料态特征的重要因素。研磨过程中受湍流流场的作用,磨料的物理特性和相对运动状态对零件的抛光效果有着直接的影响和控制。通过实验观察我们发现磨料在滚筒内的运动是极为复杂的,至今磨料运动特征对抛光过程影响机制尚不十分了解,深入研究磨料运动特征以及它对抛光过程影响对于优化机器的设计参数和加工工艺参数,进一步提高加工效率具有重要意义。
本文以在离心场中运动的整团磨料为研究对象,从理论和实验两方面分析了离心式自由磨粒研磨生产过程中整团磨料在不同参数下运动的流态特征,指出整团磨料的流态特征是影响加工效果的关键因素。
理论方面建立了基于液固两相流理论的描述整团磨料运动流态特征的数学模型,利用液固两相流动力学模型分析了不同行星传动比时磨料的流态特征。用计算流体力学的方法描绘出典型行星传动比下磨料运动特征,包括磨料的体积分数分布、压力分布、速度矢量分布等。这些特征反映出磨料团在运动过程中的变化规律。理论分析与实验结果是基本相符。指出这种理论分析方法能够代替大量的实验对做离心运动的整团磨料不同区域的浓度、速度和加速度进行分析,对于优化设计参数、提高生产率十分经济有效。
实验方面应用高速摄影手段获得了对行星整团磨料加工时磨料液固两相流运动的感性认识,描述了不同行星传动比时磨料的流态特征。通过对高速摄影结果的分析,了解了整团磨料在离心场中的运动规律,指明整团磨料在运动过程中,其滑移层的运动及前沿界面曲线的变化是影响加工效果的重要因素。改变行星传动比可以有效地改变滑移层的运动特征,从而提高生产效率。根据工件粗糙度和磨损率的测定,说明了不同行星传动比对加工过程的影响。
As a high-efficiency piece of equipment, the centrifugal free lapping is used extensively for finishing and burring of some small, abnormal parts. In fact, some key parameters of design and technology of the centrifugal free lapping are decided by experience completely so far. But optimization of key parameters is impossibly realized by experiments merely. The kinematic characteristics of the abrasive fluid will be closely related to the quality and efficiency of workpiece in the centrifugal lapping, and the planetary driver ratio of the machine is an important parameter changing the fluid characteristics.
Taking the kinematic mass abrasive as research object, this paper has analyzed theoretically and experimentally the influence of the planetary driver ratio in the processing of centrifugal polishing machine. It is pointed out that the profile of the abrasive and the path of the moving particles will be changed considerably with the alternation of planetary driver ratio. Furthermore, a series of experimental results show that the processing efficiency is affected prominently by the planetary drive ratio. The analysis conducted in this paper has put forward a proposal for improvement on the design of centrifugal polishing machine.
Theoretically, a model of two phase fluid is used as to analyze the abrasive fluid characteristics at different planetary driver ratio. The shape figures, which illustrate the abrasive movement on typical planetary driver ratio and show the distribution of abrasive volume fraction and velocity, have been plotted by the method of computational fluid mechanics. The good accordance between the numerical simulation and the experimental result points out that numerous technical experiments can be substituted by numerical simulation with computer. By utilizing the numerical method, the parameters of design and technology can be optimized economically and efficiently, which can ultimately improve the productivity.
High-speed photographing machine was employed to record the movement of abrasive flow in planetary abrasive flow processing in this paper. it is described that different planetary driver ratio on processing will bring on variational kinematic characteristics of the abrasive flow. Though qualitative analysis of the high-photograph, the movement of abrasive flow could be understood. It has been shown that the movement of the slippery layers and change of frontal interface curve are key factors affecting production efficiency and product quality. The fluid characteristics of the slippery layers can be changed obviously by altering planetary driver ratio. It will affect markedly the productivity of the machine. In the light of the experimental data, it has been explained that different planetary driver ratio will result in the change of abrasive shape. It can be seen that the flow feature of abrasives is a key factor of effecting productivity through analyzing the result of photographic experiment. Workpiece lapping experiment will verify the conclusion of photographic experiment in the light of the lapping quality of workpiece.
本文以在离心场中运动的整团磨料为研究对象,从理论和实验两方面分析了离心式自由磨粒研磨生产过程中整团磨料在不同参数下运动的流态特征,指出整团磨料的流态特征是影响加工效果的关键因素。
理论方面建立了基于液固两相流理论的描述整团磨料运动流态特征的数学模型,利用液固两相流动力学模型分析了不同行星传动比时磨料的流态特征。用计算流体力学的方法描绘出典型行星传动比下磨料运动特征,包括磨料的体积分数分布、压力分布、速度矢量分布等。这些特征反映出磨料团在运动过程中的变化规律。理论分析与实验结果是基本相符。指出这种理论分析方法能够代替大量的实验对做离心运动的整团磨料不同区域的浓度、速度和加速度进行分析,对于优化设计参数、提高生产率十分经济有效。
实验方面应用高速摄影手段获得了对行星整团磨料加工时磨料液固两相流运动的感性认识,描述了不同行星传动比时磨料的流态特征。通过对高速摄影结果的分析,了解了整团磨料在离心场中的运动规律,指明整团磨料在运动过程中,其滑移层的运动及前沿界面曲线的变化是影响加工效果的重要因素。改变行星传动比可以有效地改变滑移层的运动特征,从而提高生产效率。根据工件粗糙度和磨损率的测定,说明了不同行星传动比对加工过程的影响。
As a high-efficiency piece of equipment, the centrifugal free lapping is used extensively for finishing and burring of some small, abnormal parts. In fact, some key parameters of design and technology of the centrifugal free lapping are decided by experience completely so far. But optimization of key parameters is impossibly realized by experiments merely. The kinematic characteristics of the abrasive fluid will be closely related to the quality and efficiency of workpiece in the centrifugal lapping, and the planetary driver ratio of the machine is an important parameter changing the fluid characteristics.
Taking the kinematic mass abrasive as research object, this paper has analyzed theoretically and experimentally the influence of the planetary driver ratio in the processing of centrifugal polishing machine. It is pointed out that the profile of the abrasive and the path of the moving particles will be changed considerably with the alternation of planetary driver ratio. Furthermore, a series of experimental results show that the processing efficiency is affected prominently by the planetary drive ratio. The analysis conducted in this paper has put forward a proposal for improvement on the design of centrifugal polishing machine.
Theoretically, a model of two phase fluid is used as to analyze the abrasive fluid characteristics at different planetary driver ratio. The shape figures, which illustrate the abrasive movement on typical planetary driver ratio and show the distribution of abrasive volume fraction and velocity, have been plotted by the method of computational fluid mechanics. The good accordance between the numerical simulation and the experimental result points out that numerous technical experiments can be substituted by numerical simulation with computer. By utilizing the numerical method, the parameters of design and technology can be optimized economically and efficiently, which can ultimately improve the productivity.
High-speed photographing machine was employed to record the movement of abrasive flow in planetary abrasive flow processing in this paper. it is described that different planetary driver ratio on processing will bring on variational kinematic characteristics of the abrasive flow. Though qualitative analysis of the high-photograph, the movement of abrasive flow could be understood. It has been shown that the movement of the slippery layers and change of frontal interface curve are key factors affecting production efficiency and product quality. The fluid characteristics of the slippery layers can be changed obviously by altering planetary driver ratio. It will affect markedly the productivity of the machine. In the light of the experimental data, it has been explained that different planetary driver ratio will result in the change of abrasive shape. It can be seen that the flow feature of abrasives is a key factor of effecting productivity through analyzing the result of photographic experiment. Workpiece lapping experiment will verify the conclusion of photographic experiment in the light of the lapping quality of workpiece.
引文
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