基于特殊激光微加工方法的设备研究和开发
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摘要
缸套和活塞环是发动机中最重要的部件之一,它们的润滑和磨损状况直接影响发动机的性能。随着激光应用技术的快速发展,国外提出了激光珩磨技术的缸套处理新方法。该方法能够更好地改善缸套和活塞环的润滑性能并能提高缸套的表面硬度。另外,激光表面微造型技术以其制造加工速度快、对环境无污染以及优良的形状和尺寸控制能力被认为是表面微造型领域成功的造型方法。
然而,利用激光表面微造型技术加工金属材料时会带来较严重的负面热效应。因此本文提出了“单脉冲同点间隔多次”的激光微造型新方法。利用该方法能够高效率的加工出微观或宏观的造型形貌,且能显著减少激光加工所带来的负面热效应。
本文介绍了该加工新工艺,并根据该工艺要求分析了几种典型零件上形貌的加工方法。探讨了基于该方法控制系统的实现,阐述了系统的基本组成及控制原理。系统由激光器与光路部分、工作台部分、用于控制激光器和工作台的控制部分和辅助装置四部分组成。主要研究了基于二极管泵浦YAG激光器、工控机、运动控制卡和激光控制卡的激光珩磨专用设备的硬件系统设计,以及控制软件的开发。在硬件方面,论述了控制系统的组成和工作机理,并深入研究了MC8041P卡的内部控制原理和外部接口,提出了用一块激光控制卡进行激光器和运动控制系统的协同控制,实现了激光微造型形貌可控以及单脉冲同点间隔多次激光微加工新工艺,这是激光珩磨设备的核心技术与关键。在软件方面,论述了如何利用面向对象的编程语言和动态链接库技术实现应用程序与MC8041P间的通讯及各种加工方式的实现,保证了加工的顺利进行。最后进行了典型摩擦副的激光珩磨实验和平板的激光微造型实验,验证了设备的性能。
The tribopair of cylinder liner and piston rings is one of the most important components in the engine. Their lubrication and wear status directly affect the performance of the engine. Along with the fast development of laser application technique, a new way of cylinder liner treatment named laser honing was invented by developed country. It can improve the lubrication performance between cylinder liner and piston rings and enhance the rigidity of cylinder wall farthest. Laser surface texturing(LST) has been the most successful way in surface texturing because of its good performance such as high speed, non pollution and excellent control ability for shape and size.
However, during the laser surface texturing, high intensity of the laser beam pulse on the metal material surface results in the negative heat effect. A new processing approach of "single pulse one time, repeating at intervals" is presented in this paper. By the new approach,the micro-dimple and groove can be easily fabricated and the negative thermal effect can be reduced.
The new crafts has been introduced and the processing methods on typical parts has been discussed.The realization of control system based on the crafts has been discussed. The basic comprising and control principle of the equipment were elaborated in this paper.The designed system is composed of laser source and path system, worktable, control system and accessorial devices. The hardware system design of laser honing equipment and software development of control system is studied based on DPSS YAG laser, IPC, motion control card and Q-switch card. For hardware, the composition and working mechanism of control system is presented, then the internal controlling mechanism and outer interface of MC8041P and an Q-switch card are presented to be used for synchronization control of laser and motion control system which is the key technique of the equipment. For software, how to perform the communication between application software and MC8041P, all kinds of processing modes and display of processing track with object-oriented programming language and DLL technique are described.In the end, laser micro-texturing experiments of flat samples and laser honing experiments of representative friction-units are performed to test the performance of equipment and good results are achieved.
然而,利用激光表面微造型技术加工金属材料时会带来较严重的负面热效应。因此本文提出了“单脉冲同点间隔多次”的激光微造型新方法。利用该方法能够高效率的加工出微观或宏观的造型形貌,且能显著减少激光加工所带来的负面热效应。
本文介绍了该加工新工艺,并根据该工艺要求分析了几种典型零件上形貌的加工方法。探讨了基于该方法控制系统的实现,阐述了系统的基本组成及控制原理。系统由激光器与光路部分、工作台部分、用于控制激光器和工作台的控制部分和辅助装置四部分组成。主要研究了基于二极管泵浦YAG激光器、工控机、运动控制卡和激光控制卡的激光珩磨专用设备的硬件系统设计,以及控制软件的开发。在硬件方面,论述了控制系统的组成和工作机理,并深入研究了MC8041P卡的内部控制原理和外部接口,提出了用一块激光控制卡进行激光器和运动控制系统的协同控制,实现了激光微造型形貌可控以及单脉冲同点间隔多次激光微加工新工艺,这是激光珩磨设备的核心技术与关键。在软件方面,论述了如何利用面向对象的编程语言和动态链接库技术实现应用程序与MC8041P间的通讯及各种加工方式的实现,保证了加工的顺利进行。最后进行了典型摩擦副的激光珩磨实验和平板的激光微造型实验,验证了设备的性能。
The tribopair of cylinder liner and piston rings is one of the most important components in the engine. Their lubrication and wear status directly affect the performance of the engine. Along with the fast development of laser application technique, a new way of cylinder liner treatment named laser honing was invented by developed country. It can improve the lubrication performance between cylinder liner and piston rings and enhance the rigidity of cylinder wall farthest. Laser surface texturing(LST) has been the most successful way in surface texturing because of its good performance such as high speed, non pollution and excellent control ability for shape and size.
However, during the laser surface texturing, high intensity of the laser beam pulse on the metal material surface results in the negative heat effect. A new processing approach of "single pulse one time, repeating at intervals" is presented in this paper. By the new approach,the micro-dimple and groove can be easily fabricated and the negative thermal effect can be reduced.
The new crafts has been introduced and the processing methods on typical parts has been discussed.The realization of control system based on the crafts has been discussed. The basic comprising and control principle of the equipment were elaborated in this paper.The designed system is composed of laser source and path system, worktable, control system and accessorial devices. The hardware system design of laser honing equipment and software development of control system is studied based on DPSS YAG laser, IPC, motion control card and Q-switch card. For hardware, the composition and working mechanism of control system is presented, then the internal controlling mechanism and outer interface of MC8041P and an Q-switch card are presented to be used for synchronization control of laser and motion control system which is the key technique of the equipment. For software, how to perform the communication between application software and MC8041P, all kinds of processing modes and display of processing track with object-oriented programming language and DLL technique are described.In the end, laser micro-texturing experiments of flat samples and laser honing experiments of representative friction-units are performed to test the performance of equipment and good results are achieved.
引文
1 王玉英.飞秒光纤激光器的发展及其工业应用.光机电信息,2006(2):29-35
2 孟小霞.规则表面微造型的激光加工和摩擦特性研究,江苏大学硕士学位论文.
3 杨恒宗,傅星,张师伟等.基于DSP与单片机的激光加工数控系统的研究.组合机床与自动化加工技术,2005(12):35-37
4 陈小亮,任乃飞,王群.飞秒激光双光子聚合三维微细加工技术及系统的研发.机械制造,2006(2):27-30
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6 Erdemir.A,Kovalchenko.A,Erck.R," Laser texturing of materials",FY 2004progress Report,2004:71-76
7 Xiaolei W and Koji K.,"Improving the anti-seizure ability of Sic seal in water with RIE texturing",Tribology Letters,2002,14(4):275-301
8 L.S.Stephens,"Deterministic micro asperities on bearings and seals using a modified LIGA process",Journal of Engineering for Gas Turbines and power,2005(126):147-154
9 Izhak Etsion.State of the Art in Laser Surface Texturing[J].ASME J.Tribol,2005,127:248-252
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12 Kim Won-Jong,Verma,Shobhit.Multi-axis maglev positioner resolution over large travel range.American Society of Engineers,2005,74(2)PART B:1295 - 1305
13 邓锡铭.激光应用的回顾与展望.激光与红外,1996,(04):65-69
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21 孙晓慧等飞秒激光加工最新进展.激光与光电子学进展,41(9):37-45(2004)
22 Hoppermann,A.and Kordt,M.,"Tribological Optimisation Using Laser Structured Contact Surface," O+P Oethydraulik and Pneumatik,2002,46,9
23 Gehring Gmbh&Co Maschf.Method of Finishing a Surface of a Workpiece.US5441439.1995
24 Gehring Gmbh&Co Maschf.Method of Fine-maching a Workpiece Surface to be Supplied with a Lubricant During Operation of the Workpiece.US5630953.1997
25 Ulrich Klink et al.New technologies of honing.SME paper.1998
26 Klink,u.气缸工作表面的激光珩磨.国外内燃机.1998(2):50-53
27 Klink,U.and Flores,G.,"New technologies of honing",Technical Paper - Society of Manufacturing Engineers.MR,1998:10
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31 Etsion,I.,and Halperin,G.,“A Laser Surface Textured Hydrostatic Mechanical Seal,” Tribol.Trans.,2002,45(3):430-434
32 Ronen,A.and Etsion,I.“Friction-Reducing Surface-Texturing in Reciprocating Automotive Components,” Tribology Transactions,2001,44(3):359-366
33 Ryk,G.,Kligerman,Y.,and Etsion,I.,“Experimental Investigation of Laser Surface Texturing for Reciprocating Automotive Components,” Tribol.Trans.,2002,45(4):444-449
34 Kligerman,Y.,Shinkarenko A.,Etsion,I.,“Improving Tribological Performance of Piston Rings by Partial Surface Texturing,” 2004 AIMETA International Tribology Conference,(2004)
35 Brizmer,V.,Kligerman,Y.,and Etsion,I.,“A Laser Surface Textured Parallel Thrust Bearing,” Tribol.Trans.,2003,46(3):397-403
36 Etsion,I.,Halperin,G.,Brizmer,V.,and Kligerman,Y.,“Experimental investigation of laser surface textured parallel thrust bearings,” Tribol.Lett.,2004,17(2):295-300
37 符永宏,叶云霞,张永康.用于显著改善摩擦副润滑状态的激光珩磨技术.机械工程学报,2002(2):115-117
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2 孟小霞.规则表面微造型的激光加工和摩擦特性研究,江苏大学硕士学位论文.
3 杨恒宗,傅星,张师伟等.基于DSP与单片机的激光加工数控系统的研究.组合机床与自动化加工技术,2005(12):35-37
4 陈小亮,任乃飞,王群.飞秒激光双光子聚合三维微细加工技术及系统的研发.机械制造,2006(2):27-30
5 蔡兰,符永宏,叶云霞.激光珩磨技术在气缸表面处理中的应用.江苏大学学报,2002(1):5-8
6 Erdemir.A,Kovalchenko.A,Erck.R," Laser texturing of materials",FY 2004progress Report,2004:71-76
7 Xiaolei W and Koji K.,"Improving the anti-seizure ability of Sic seal in water with RIE texturing",Tribology Letters,2002,14(4):275-301
8 L.S.Stephens,"Deterministic micro asperities on bearings and seals using a modified LIGA process",Journal of Engineering for Gas Turbines and power,2005(126):147-154
9 Izhak Etsion.State of the Art in Laser Surface Texturing[J].ASME J.Tribol,2005,127:248-252
10 于新奇,蔡仁良.激光加工多孔端面机械密封.河北科技大学学报,2004(1):26-28
11 何松,蔡仁良.激光纹理技术在机械密封中的应用.化工设备与防腐蚀,2002(2):115-117
12 Kim Won-Jong,Verma,Shobhit.Multi-axis maglev positioner resolution over large travel range.American Society of Engineers,2005,74(2)PART B:1295 - 1305
13 邓锡铭.激光应用的回顾与展望.激光与红外,1996,(04):65-69
14 戚文军,何艳兵,刘斌,黄科,张勤学,陈一清.微机控制激光加工专机的 研制.广东有色金属学报,2001(2):146-150
15 王先述,吴丹,刘成影.精密加工和超精密加工计一数综述.中国机械工程,1999(5):570-578
16 薛迎红.激光器件一气体激光器.中国光学与应用光学文摘,2006(1):16-17
17 Lic.Argumentm.Micromachining with femtosecond 250nm laser pulses[J].Proc SPIE,2000,4087:1194-1200
18 Nadeem H.Rizvi.Femtosecond laser micromachining:Current status and applications.RIKEN review,2003,50:107-112
19 Carey J E.Crouch C H,Eric Mazur.Femtosecond-laser-assisted microstructuring of silicon surfaces for new optoelectronics applications.Opt.& Phot.News,2003,2:32-36
20 黄峻峰飞秒激光开辟了新的微细加工领域.光机电信息,10(1):10-13(2004)
21 孙晓慧等飞秒激光加工最新进展.激光与光电子学进展,41(9):37-45(2004)
22 Hoppermann,A.and Kordt,M.,"Tribological Optimisation Using Laser Structured Contact Surface," O+P Oethydraulik and Pneumatik,2002,46,9
23 Gehring Gmbh&Co Maschf.Method of Finishing a Surface of a Workpiece.US5441439.1995
24 Gehring Gmbh&Co Maschf.Method of Fine-maching a Workpiece Surface to be Supplied with a Lubricant During Operation of the Workpiece.US5630953.1997
25 Ulrich Klink et al.New technologies of honing.SME paper.1998
26 Klink,u.气缸工作表面的激光珩磨.国外内燃机.1998(2):50-53
27 Klink,U.and Flores,G.,"New technologies of honing",Technical Paper - Society of Manufacturing Engineers.MR,1998:10
28 Ludolf Herbst,Horst Lindner,Mike Heglin and Tony Hoult,"Targeting diesel engine efficiency",Industrial Laser Solutions,2004,10:32-35
29 Etsion,I.,Kligerman,Y.,and Halperin,G.,"Analytical and Experimental Investigation of Laser-Textured Mechanical Seal Faces," Tribol.Trans,1999,42: 511-516
30 Etsion,I.,“Improving Tribological Performance of Mechanical Seals by Laser Surface Texturing,” Proceedings of the 17th International Pump Users Symposium,2000:17-22
31 Etsion,I.,and Halperin,G.,“A Laser Surface Textured Hydrostatic Mechanical Seal,” Tribol.Trans.,2002,45(3):430-434
32 Ronen,A.and Etsion,I.“Friction-Reducing Surface-Texturing in Reciprocating Automotive Components,” Tribology Transactions,2001,44(3):359-366
33 Ryk,G.,Kligerman,Y.,and Etsion,I.,“Experimental Investigation of Laser Surface Texturing for Reciprocating Automotive Components,” Tribol.Trans.,2002,45(4):444-449
34 Kligerman,Y.,Shinkarenko A.,Etsion,I.,“Improving Tribological Performance of Piston Rings by Partial Surface Texturing,” 2004 AIMETA International Tribology Conference,(2004)
35 Brizmer,V.,Kligerman,Y.,and Etsion,I.,“A Laser Surface Textured Parallel Thrust Bearing,” Tribol.Trans.,2003,46(3):397-403
36 Etsion,I.,Halperin,G.,Brizmer,V.,and Kligerman,Y.,“Experimental investigation of laser surface textured parallel thrust bearings,” Tribol.Lett.,2004,17(2):295-300
37 符永宏,叶云霞,张永康.用于显著改善摩擦副润滑状态的激光珩磨技术.机械工程学报,2002(2):115-117
38 蔡兰,符永宏,叶云霞.激光珩磨技术在气缸表面处理中的应用.江苏大学学报,2002(1):5-8
39 陆华才,符永宏.气缸套珩磨工艺的发展.内燃机,2003(6):8-9
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