功率超声振动珩磨技术的基础与应用研究
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摘要
普通珩磨效率较低,易产生噪声和油石堵塞,从而导致油石寿命低,尺寸精度难以控制,需频繁更换油石,由于配件互换性差,对工人技术级别要求高,劳动强度大,废品率高,生产效率低,致使这种精密加工方法的应用受到限制。本研究就是针对这种现状,将超声振动附加在珩磨油石条上,使得每一颗磨粒在磨削的同时进行高频振动,从而实现脉冲磨削,这就是功率超声振动珩磨技术。本论文在系统总结了国内外大量文献资料的基础上,通过理论分析和试验研究相结合的方法,在功率超声珩磨加工理论研究的基础上,研制成功了功率超声珩磨装置和新型磨削液发生装置,特别是功率超声珩磨装置中谐振系统的研究和新型磨削液发生装置中特殊多段式喷嘴的研制,有新意,论文关于功率超声振动珩磨加工机理和工艺的研究,丰富和完善了功率超声珩磨加工的理论成果。论文所完成的有创意的基础与应用研究工作可以概括为:
1.在普通珩磨切削加工理论的基础上,进行了功率超声振动珩磨切削机理的研究和分析,确定了纵向和径向功率超声振动珩磨的临界速度;同时对功率超声振动磨料空切削现象进行了分析。并在分析功率超声振动珩磨的磨粒运动的基础上,给出功率超声珩磨材料去除率的理论公式。材料去除量的理论分析和试验研究均表明,在同比条件下,超声珩磨的磨削效率是普通珩磨的磨削效率的2.5倍。
2、提出了一种有新意的功率超声珩磨装置的设计理念,即以珩磨孔径为参数的谐振系统的设计方法,研制成功了新型立式功率超声振动珩磨装置,同时将超短型专用压电换能器用于功率超声珩磨设计中,把有限元分析技术引入功率超声珩磨谐振系统动力特性的研究中,有限元分析结果所得结构系统的固有频率和相应振型,与试验实测数据基本吻合。通过仿真研究和试验研究确定的振动系统的振动参数、结构尺寸是科学可行的,解决了功率超声振动珩磨应用中的关键问题。
3、研制成功了新型磨削液供液系统及装置,特别是研制成功了关键部件——特殊多段式喷嘴,填补了国内空白。研究了新型磨削液的形成机理和物理特性,探讨了其优良的冷却润滑性能的作用机理。完成了新型磨削液在功率超声珩磨中磨削性能的试验研究,研究结果表明:新型磨削液具有良好的润滑性能,在加工精度和油石寿命方面具有明显优势,因此适用于功率超声珩磨加工。
4、完成了普通珩磨和功率超声珩磨对比工艺试验研究,研究结果表明:功率超声珩磨比普通珩磨具有更小的表面粗糙度值。完成了功率超声振动珩磨加工工艺优化试验研究,确定了可适应加工对象的最佳油石参数和工艺参数,应用优化参数加工后的新型缸套与原缸套进行台架性能的对比试验结果表明,已完全达到并超过了该项目预定的要求指标,也说明采用自行研制的功率超声振动珩磨加工装置和新型磨削液确可很好的适应生产现场的加工要求。
The efficiency of the ordinary honing is low and it produces big noise and chocking-up easily which causes lots of deficiency such as loss of life for oil-stone, dimensional accuracy controls with difficulty, fittings interchangeable badly, replace the oil-stone frequently, high technology requests and labor intensity to the workers, high rejection rate and low efficiency. Thus the application of this processing method is restricted. This paper aims at this situation and proposed a method to solve them. It attaches ultrasonic vibration on oil stone strip which causes high-frequency vibration to each abrasive when it grinding simultaneously. It realizes pulse grindings, so is the power ultrasonic vibration honing technology.This dissertation summarized the literature of domestic and foreign, unified fundamental research and experimental study, based on the theoretical research of the power ultrasonic vibration honing, finally developed the power-ultrasonic-honing installment and new machine-finishing-fluid generator successfully. And the resonance system in the honing installment and the multi-zone injecting nozzle in the machine-finishing-fluid generator filled the domestic blank. The research also studies further on the processing mechanism and the craft to the power ultrasonic vibration which richen the theory achievement of power ultrasonic vibration.
1. On the base of ordinary honing machining theory, this dissertation analyzed the cutting mechanism and the cutting motion, determined the longitudinal and the radial critical speed, researched the spatial cutting phenomenon. With the analysis of abrasive grain motion, this dissertation produced the material removing rate theoretical formula of power ultrasonic honing. The correlation experimental showed that the bigger the oil stone particle, the higher the grinding efficiency. And if in the same size, the efficiency of ultrasonic vibration honing is 2.5 than that of ordinary honing, which meets the theoretical analysis.
2. This dissertation firstly proposed a kind of new design idea to the ultrasonic vibration honing installment, that is using hone aperture as the parameter to design the resonance system and developing the new vertical power ultrasonic vibration honing installment successfully. The installment is adopted special-purpose piezoelectric transducer for the first time. This dissertation firstly introduced the finite element analysis technology into the dynamic properties of the power ultrasonic honing system. The natural frequency and corresponding mode from the result of the finite element analysis is approaches to the experimental data. This dissertion showed that the definition of vibration parameter and physical dimension through the simulation research and the experimental study is feasible. It solved the key problem in the application of the power ultrasonic vibration honing.
3. This dissertation developed the new grinding-fluid generator successfully. Specially, the multi-zone injecting nozzle----the key component of the generator has filled the domestic blank. It also studied the new grinding fluid formation mechanism and the physical property, and discussed its cooling lubricity action mechanism.The dissertation completed the experimental research of the new grinding fluid grinding performance in power supersonic honing . The results shows that the new grinding fluid has good lubricating property, it has obvious superiority in working accuracy and in life of oil stone, therefore it is suitable to the power supersonic honing processing.
4. This dissertation compared the craft testing between ordinary honing and the power supersonic honing, it has much smaller surface roughness value than ordinary honing . The dissertation complete the processing craft optimization experiment of the ultrasonic vibration honing, determined the optimally oil stone parameter and the craft parameter when processing object. After contrast bench test between the original cylinder jacket and the new cylinder jacket, results completely achieved the requested arm. This explained that the power ultrasonic vibration installment and the cooling-lubricating arrangement can meet the scene processing request.
1.在普通珩磨切削加工理论的基础上,进行了功率超声振动珩磨切削机理的研究和分析,确定了纵向和径向功率超声振动珩磨的临界速度;同时对功率超声振动磨料空切削现象进行了分析。并在分析功率超声振动珩磨的磨粒运动的基础上,给出功率超声珩磨材料去除率的理论公式。材料去除量的理论分析和试验研究均表明,在同比条件下,超声珩磨的磨削效率是普通珩磨的磨削效率的2.5倍。
2、提出了一种有新意的功率超声珩磨装置的设计理念,即以珩磨孔径为参数的谐振系统的设计方法,研制成功了新型立式功率超声振动珩磨装置,同时将超短型专用压电换能器用于功率超声珩磨设计中,把有限元分析技术引入功率超声珩磨谐振系统动力特性的研究中,有限元分析结果所得结构系统的固有频率和相应振型,与试验实测数据基本吻合。通过仿真研究和试验研究确定的振动系统的振动参数、结构尺寸是科学可行的,解决了功率超声振动珩磨应用中的关键问题。
3、研制成功了新型磨削液供液系统及装置,特别是研制成功了关键部件——特殊多段式喷嘴,填补了国内空白。研究了新型磨削液的形成机理和物理特性,探讨了其优良的冷却润滑性能的作用机理。完成了新型磨削液在功率超声珩磨中磨削性能的试验研究,研究结果表明:新型磨削液具有良好的润滑性能,在加工精度和油石寿命方面具有明显优势,因此适用于功率超声珩磨加工。
4、完成了普通珩磨和功率超声珩磨对比工艺试验研究,研究结果表明:功率超声珩磨比普通珩磨具有更小的表面粗糙度值。完成了功率超声振动珩磨加工工艺优化试验研究,确定了可适应加工对象的最佳油石参数和工艺参数,应用优化参数加工后的新型缸套与原缸套进行台架性能的对比试验结果表明,已完全达到并超过了该项目预定的要求指标,也说明采用自行研制的功率超声振动珩磨加工装置和新型磨削液确可很好的适应生产现场的加工要求。
The efficiency of the ordinary honing is low and it produces big noise and chocking-up easily which causes lots of deficiency such as loss of life for oil-stone, dimensional accuracy controls with difficulty, fittings interchangeable badly, replace the oil-stone frequently, high technology requests and labor intensity to the workers, high rejection rate and low efficiency. Thus the application of this processing method is restricted. This paper aims at this situation and proposed a method to solve them. It attaches ultrasonic vibration on oil stone strip which causes high-frequency vibration to each abrasive when it grinding simultaneously. It realizes pulse grindings, so is the power ultrasonic vibration honing technology.This dissertation summarized the literature of domestic and foreign, unified fundamental research and experimental study, based on the theoretical research of the power ultrasonic vibration honing, finally developed the power-ultrasonic-honing installment and new machine-finishing-fluid generator successfully. And the resonance system in the honing installment and the multi-zone injecting nozzle in the machine-finishing-fluid generator filled the domestic blank. The research also studies further on the processing mechanism and the craft to the power ultrasonic vibration which richen the theory achievement of power ultrasonic vibration.
1. On the base of ordinary honing machining theory, this dissertation analyzed the cutting mechanism and the cutting motion, determined the longitudinal and the radial critical speed, researched the spatial cutting phenomenon. With the analysis of abrasive grain motion, this dissertation produced the material removing rate theoretical formula of power ultrasonic honing. The correlation experimental showed that the bigger the oil stone particle, the higher the grinding efficiency. And if in the same size, the efficiency of ultrasonic vibration honing is 2.5 than that of ordinary honing, which meets the theoretical analysis.
2. This dissertation firstly proposed a kind of new design idea to the ultrasonic vibration honing installment, that is using hone aperture as the parameter to design the resonance system and developing the new vertical power ultrasonic vibration honing installment successfully. The installment is adopted special-purpose piezoelectric transducer for the first time. This dissertation firstly introduced the finite element analysis technology into the dynamic properties of the power ultrasonic honing system. The natural frequency and corresponding mode from the result of the finite element analysis is approaches to the experimental data. This dissertion showed that the definition of vibration parameter and physical dimension through the simulation research and the experimental study is feasible. It solved the key problem in the application of the power ultrasonic vibration honing.
3. This dissertation developed the new grinding-fluid generator successfully. Specially, the multi-zone injecting nozzle----the key component of the generator has filled the domestic blank. It also studied the new grinding fluid formation mechanism and the physical property, and discussed its cooling lubricity action mechanism.The dissertation completed the experimental research of the new grinding fluid grinding performance in power supersonic honing . The results shows that the new grinding fluid has good lubricating property, it has obvious superiority in working accuracy and in life of oil stone, therefore it is suitable to the power supersonic honing processing.
4. This dissertation compared the craft testing between ordinary honing and the power supersonic honing, it has much smaller surface roughness value than ordinary honing . The dissertation complete the processing craft optimization experiment of the ultrasonic vibration honing, determined the optimally oil stone parameter and the craft parameter when processing object. After contrast bench test between the original cylinder jacket and the new cylinder jacket, results completely achieved the requested arm. This explained that the power ultrasonic vibration installment and the cooling-lubricating arrangement can meet the scene processing request.
引文
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