软性磨粒流近壁区域微切削机理及其控制方法研究
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摘要
模具制造过程中常会出现尺寸细微，结构复杂的异型面，可将其称之为模具的结构化表面。传统有工具抛光加工方法难以对模具结构化表面进行全面的精密加工，而现有的流体加工方法受到加工工具及装备结构的限制，在面向模具结构化表面加工时仍存在难以克服的困难。
针对此问题，本文提出一种基于近壁区理论的软性磨粒流加工分析方法。以这种加工方法为基础，本文首先基于可实现湍动能-耗散率(k-ε)湍流模型对软性磨粒流在流道中的运动进行建模，并分析软性磨粒流在近壁区的运动特性，对可实现k-ε湍流模型进行改进；其次通过计算流体力学方法对软性磨粒流在流道内的流动特性进行数值模拟分析；然后以仿真结果为基础进行了磨粒运动观测实验；最后搭建软性磨粒流加工实验台，进行工件的光整加工实验。本文内容主要从以下几个方面展开：
(1)针对可实现k-ε湍流模型与标准k-ε湍流模型所应用场合、描述特点的不同，对两者进行分析，前者对描述射流和混合流的自由流动，以及复杂流道中的流动都有着更好的表现，所以本文选择可实现k-ε湍流模型作为软性磨粒流的基本物理模型；对软性磨粒流近壁区的特征进行分析，并对由软性磨粒流加工特性所引起的湍流耗散进行研究，基于研究结果，对可实现k-ε湍流模型中的耗散率方程进行修正，所得到修正后的可实现k-ε湍流模型能够较为完整的对软性磨粒流在加工流道中的特性进行描述；对固体颗粒的受力情况进行分析，进而对软性磨粒流在近壁区的微切削机理进行研究。
(2)基于可实现k-ε湍流模型，采用离散相模型建立软性磨粒流动力学模型，基于该模型对加工中所涉及到的影响因素进行仿真实验研究。首先以U型流道为例，主要对软性磨粒流的速度、压力、颗粒特性，湍动能、湍流耗散率等湍流参数，以及影响工件加工后表面纹理的颗粒运动轨迹等进行数值模拟分析。通过对上述因素进行研究后得到，软性磨粒流离散相的压力衰减程度与入口速度成反比，且在流道内的运动轨迹呈无序状态；并得到了适用于软性磨粒流加工的最佳颗粒尺寸；然后以汽车模具中的典型结构化表面所构成约束流道进行数值模拟分析，通过对不同体积分数的软性磨粒流在流道中动压力分布、速度矢量分布以及湍流耗散率分布的研究，证明了软性磨粒流加工方法的有效性。
(3)以数值模拟分析结果为基础，采用不同配比的切削液、分散剂和水，对软性磨粒流溶液进行调配，并设计了软性磨粒流离散颗粒相的观测实验。对软性磨粒流试剂进行调配实验；利用高速摄像机对软性磨粒流在流道中的固体颗粒进行运动轨迹观测运动进行观察；采用粒子图像测速方法对软性磨粒流的流场进行测量，通过区域分析法得到了流场的速度矢量、涡量分布等信息，证明了在此条件下，软性磨粒流的运动形态符合湍流特征，能够实现对模具结构化表面的光整加工。软性磨粒流观测实验结果与数值模拟结果相符，为下一步基于软性磨粒流的加工实验奠定了理论基础。
(4)基于理论分析、数值模拟及观测实验结果，搭建基于变频调速系统的模具结构化表面光整加工平台，该加工平台能够实现对水泵的精确调速，使软性磨粒流流态过渡更加准确。经过20小时的光整加工后，加工结果表明：软性磨粒流能够在不改变工件原有形貌的基础上，有效改善模具结构化表面的表面质量，并且能够去除原有机械加工的痕迹，使得工件表面更加平整，加工后工件入口处粗糙度为0.312μm，出口处粗糙度为0.556μm，工件整体质量减少0.2g。加工实验结果证明了软性磨粒流加工方法应用在模具结构化表面光整加工上的可行性和有效性。
(5)基于普林斯顿方程对影响软性磨粒流加工的颗粒硬度、尺寸、颗粒与壁面碰撞角度、加工时间等因素进行分析，并对普林斯顿方程进行改进，得到适用于软性磨粒流光整加工的材料去除模型，使其能够准确的计算出软性磨粒流对工件的去除量。
During the course of mold manufacture, lots of heteromorphous surfaces are involved,which are of complicated structure and tiny scale, and can be defined as structural surface.Owing to special profile of structural surface, its finishing cannot be realized by traditionalmethods. Aiming at the problem, several fluidic finishing methods are put forward, but thefinishing system structure of these finishing methods is the biggest drawback for increasingmachining precision, so the satisfied finishing results cannot be obtained by these methods.
In allusion to the problem, a new no-tool precision finishing method based onsolid-liquid two phase softness abrasive flow (SAF) is brought forward in this paper. Basedon this method, realizable k-ε model is used to describe the flow field of SAF, and therealizable k-ε model is modified by analyzing the motion characteristics of SAF in the nearwall area. The flow characteristic of SAF is numerically simulated by CFD, and based on thesimulation results, observational experiment of particles motion has been carried out. Finally,SAF experimental platform is constructed, and the finishing experiment which oriented tomold structural surface can be realized. Main work of this dissertation is shown as follows:
(1) Realizable k-ε model has been chosen to describe SAF compared to standard k-εmodel, because the former model can be better reflect the characteristics of jet flow, free flowand the flow in complex passage. Analyzed the flowing features of SAF in near wall area, anddissipation rate equation of realizable k-ε model is modified based on the analyzing results;the new model can reflect the turbulence dissipation which caused by the finishing in the nearwall area previously, so that the finishing characteristics of SAF can be accurate described bythe model. Based on an analysis of the forces acted on the particles, micro-cutting mechanismof SAF finishing method has been studied.
(2) Based on realizable k-ε model, discrete phase model (DPM) is used to establish thekinetic model of SAF, and influencing factors which effect the finishing are simulated. TakingU-shaped restrained flow passage as instance, the variation trends of SAF turbulentparameters and flow passage pressure distribution with different inlet velocities are studied,and motion trails of particles are also simulated. Numerical simulation results derive that pressure decrement of solid phase in flow passage is inversely proportion to inlet velocity, andmotion trails of particles are disorderly and stochastic, which are the sufficient conditions ofSAF finishing. The automobile mold is simulated as a typical structural surface, and SAFdynamic pressure, velocity and turbulent dissipation distribution with different volumefraction are acquired, effectiveness of SAF finishing method has been proved by thesesimulation results.
(3) Based on the simulation results, SAF has been mixed with different proportioncutting fluid, dispersing agent and water, and observational experiment of particles has beendesigned. High-speed camera is used to observe the motion trails of solid phase, and velocityvector and vorticity of SAF flow field are obtained by PIV. Particles observational experimentshows that particle motion satisfied requirements of SAF finishing, and feasibility of SAFshould be proved theoretically.
(4) Finishing platform which oriented to mold structural surface has been constructed,this platform can make water pump speed governing accurately, so exact transition of SAFflow regime can be realized. Experiment results show that SAF method can improve surfacequality of mold structural surface without change the morphology, and the trace of machiningcan be eliminated. After finishing, Ra of inlet is0.312μm, Ra of outlet is0.556μm and theweight of workpiece reduced0.2g. Experimental results have demonstrated the effectivenessof SAF finishing method.
(5) Hardness and size of particles, collision angles between particle and surface, andfinishing time are analyzed based on Preston equation; and the equation has been improved tosuit for SAF finishing. Removal model of SAF finishing is derived based on the improvedequation, and material removal by this finishing method can be obtained.
针对此问题，本文提出一种基于近壁区理论的软性磨粒流加工分析方法。以这种加工方法为基础，本文首先基于可实现湍动能-耗散率(k-ε)湍流模型对软性磨粒流在流道中的运动进行建模，并分析软性磨粒流在近壁区的运动特性，对可实现k-ε湍流模型进行改进；其次通过计算流体力学方法对软性磨粒流在流道内的流动特性进行数值模拟分析；然后以仿真结果为基础进行了磨粒运动观测实验；最后搭建软性磨粒流加工实验台，进行工件的光整加工实验。本文内容主要从以下几个方面展开：
(1)针对可实现k-ε湍流模型与标准k-ε湍流模型所应用场合、描述特点的不同，对两者进行分析，前者对描述射流和混合流的自由流动，以及复杂流道中的流动都有着更好的表现，所以本文选择可实现k-ε湍流模型作为软性磨粒流的基本物理模型；对软性磨粒流近壁区的特征进行分析，并对由软性磨粒流加工特性所引起的湍流耗散进行研究，基于研究结果，对可实现k-ε湍流模型中的耗散率方程进行修正，所得到修正后的可实现k-ε湍流模型能够较为完整的对软性磨粒流在加工流道中的特性进行描述；对固体颗粒的受力情况进行分析，进而对软性磨粒流在近壁区的微切削机理进行研究。
(2)基于可实现k-ε湍流模型，采用离散相模型建立软性磨粒流动力学模型，基于该模型对加工中所涉及到的影响因素进行仿真实验研究。首先以U型流道为例，主要对软性磨粒流的速度、压力、颗粒特性，湍动能、湍流耗散率等湍流参数，以及影响工件加工后表面纹理的颗粒运动轨迹等进行数值模拟分析。通过对上述因素进行研究后得到，软性磨粒流离散相的压力衰减程度与入口速度成反比，且在流道内的运动轨迹呈无序状态；并得到了适用于软性磨粒流加工的最佳颗粒尺寸；然后以汽车模具中的典型结构化表面所构成约束流道进行数值模拟分析，通过对不同体积分数的软性磨粒流在流道中动压力分布、速度矢量分布以及湍流耗散率分布的研究，证明了软性磨粒流加工方法的有效性。
(3)以数值模拟分析结果为基础，采用不同配比的切削液、分散剂和水，对软性磨粒流溶液进行调配，并设计了软性磨粒流离散颗粒相的观测实验。对软性磨粒流试剂进行调配实验；利用高速摄像机对软性磨粒流在流道中的固体颗粒进行运动轨迹观测运动进行观察；采用粒子图像测速方法对软性磨粒流的流场进行测量，通过区域分析法得到了流场的速度矢量、涡量分布等信息，证明了在此条件下，软性磨粒流的运动形态符合湍流特征，能够实现对模具结构化表面的光整加工。软性磨粒流观测实验结果与数值模拟结果相符，为下一步基于软性磨粒流的加工实验奠定了理论基础。
(4)基于理论分析、数值模拟及观测实验结果，搭建基于变频调速系统的模具结构化表面光整加工平台，该加工平台能够实现对水泵的精确调速，使软性磨粒流流态过渡更加准确。经过20小时的光整加工后，加工结果表明：软性磨粒流能够在不改变工件原有形貌的基础上，有效改善模具结构化表面的表面质量，并且能够去除原有机械加工的痕迹，使得工件表面更加平整，加工后工件入口处粗糙度为0.312μm，出口处粗糙度为0.556μm，工件整体质量减少0.2g。加工实验结果证明了软性磨粒流加工方法应用在模具结构化表面光整加工上的可行性和有效性。
(5)基于普林斯顿方程对影响软性磨粒流加工的颗粒硬度、尺寸、颗粒与壁面碰撞角度、加工时间等因素进行分析，并对普林斯顿方程进行改进，得到适用于软性磨粒流光整加工的材料去除模型，使其能够准确的计算出软性磨粒流对工件的去除量。
During the course of mold manufacture, lots of heteromorphous surfaces are involved,which are of complicated structure and tiny scale, and can be defined as structural surface.Owing to special profile of structural surface, its finishing cannot be realized by traditionalmethods. Aiming at the problem, several fluidic finishing methods are put forward, but thefinishing system structure of these finishing methods is the biggest drawback for increasingmachining precision, so the satisfied finishing results cannot be obtained by these methods.
In allusion to the problem, a new no-tool precision finishing method based onsolid-liquid two phase softness abrasive flow (SAF) is brought forward in this paper. Basedon this method, realizable k-ε model is used to describe the flow field of SAF, and therealizable k-ε model is modified by analyzing the motion characteristics of SAF in the nearwall area. The flow characteristic of SAF is numerically simulated by CFD, and based on thesimulation results, observational experiment of particles motion has been carried out. Finally,SAF experimental platform is constructed, and the finishing experiment which oriented tomold structural surface can be realized. Main work of this dissertation is shown as follows:
(1) Realizable k-ε model has been chosen to describe SAF compared to standard k-εmodel, because the former model can be better reflect the characteristics of jet flow, free flowand the flow in complex passage. Analyzed the flowing features of SAF in near wall area, anddissipation rate equation of realizable k-ε model is modified based on the analyzing results;the new model can reflect the turbulence dissipation which caused by the finishing in the nearwall area previously, so that the finishing characteristics of SAF can be accurate described bythe model. Based on an analysis of the forces acted on the particles, micro-cutting mechanismof SAF finishing method has been studied.
(2) Based on realizable k-ε model, discrete phase model (DPM) is used to establish thekinetic model of SAF, and influencing factors which effect the finishing are simulated. TakingU-shaped restrained flow passage as instance, the variation trends of SAF turbulentparameters and flow passage pressure distribution with different inlet velocities are studied,and motion trails of particles are also simulated. Numerical simulation results derive that pressure decrement of solid phase in flow passage is inversely proportion to inlet velocity, andmotion trails of particles are disorderly and stochastic, which are the sufficient conditions ofSAF finishing. The automobile mold is simulated as a typical structural surface, and SAFdynamic pressure, velocity and turbulent dissipation distribution with different volumefraction are acquired, effectiveness of SAF finishing method has been proved by thesesimulation results.
(3) Based on the simulation results, SAF has been mixed with different proportioncutting fluid, dispersing agent and water, and observational experiment of particles has beendesigned. High-speed camera is used to observe the motion trails of solid phase, and velocityvector and vorticity of SAF flow field are obtained by PIV. Particles observational experimentshows that particle motion satisfied requirements of SAF finishing, and feasibility of SAFshould be proved theoretically.
(4) Finishing platform which oriented to mold structural surface has been constructed,this platform can make water pump speed governing accurately, so exact transition of SAFflow regime can be realized. Experiment results show that SAF method can improve surfacequality of mold structural surface without change the morphology, and the trace of machiningcan be eliminated. After finishing, Ra of inlet is0.312μm, Ra of outlet is0.556μm and theweight of workpiece reduced0.2g. Experimental results have demonstrated the effectivenessof SAF finishing method.
(5) Hardness and size of particles, collision angles between particle and surface, andfinishing time are analyzed based on Preston equation; and the equation has been improved tosuit for SAF finishing. Removal model of SAF finishing is derived based on the improvedequation, and material removal by this finishing method can be obtained.
引文
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