软性磨粒流加工特性及近壁区域微切削机理
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摘要
软性磨粒流加工是一种能够有效解决模具结构化表面光整加工的新方法。基于软性磨粒流光整加工的特点,对软性磨粒流中颗粒对壁面的微切削机理进行研究。以普林斯顿方程为基础,对固体相颗粒在流体中的受力进行分析,进而分析颗粒对壁面的微切削机理。通过对汽车模具中的典型结构化表面进行结构简化,得到用于数值模拟及加工试验的流道的物理模型,采用可实现k-ε湍流模型对软性磨粒流在流道中的压力、速度流场的分布进行数值分析;搭建软性磨粒流加工试验平台并进行20 h加工试验,加工结果证明微切削机理分析的正确性,试验对比结果证明软性磨粒流加工方法可以实现细微尺寸结构化表面的光整加工,有效提高加工的精度。
Softness abrasive flow(SAF) machining is a novel finishing method for mold structural surface. Based on the characteristics of SAF machining, the micro-cutting mechanism of particles to surface has been analyzed. Force analysis for the solid phase which flowed with SAF is carried out based on the Preston equation, and then, the micro-cutting mechanism of particles to surface has been analyzed. Typical structural surface of motor mold has been simplified, and the physical model used to numerical analyzing and finishing is obtained, and realizable k-ε model is used for numerical analyzing pressure and velocity distribution of SAF flow field. SAF experimental platform is constructed, the validity of micro-cutting mechanism analyzing is proved, and experiment results show that SAF can improve surface accuracy of tiny scale mould structural surface effectively.
Softness abrasive flow(SAF) machining is a novel finishing method for mold structural surface. Based on the characteristics of SAF machining, the micro-cutting mechanism of particles to surface has been analyzed. Force analysis for the solid phase which flowed with SAF is carried out based on the Preston equation, and then, the micro-cutting mechanism of particles to surface has been analyzed. Typical structural surface of motor mold has been simplified, and the physical model used to numerical analyzing and finishing is obtained, and realizable k-ε model is used for numerical analyzing pressure and velocity distribution of SAF flow field. SAF experimental platform is constructed, the validity of micro-cutting mechanism analyzing is proved, and experiment results show that SAF can improve surface accuracy of tiny scale mould structural surface effectively.
引文
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[10]计时鸣,李琛,谭大鹏,等.基于Preston方程的软性磨粒流加工特性[J].机械工程学报,2011,47(17):156-163.JI Shiming,LI Chen,TAN Dapeng,et al.Study on machinability of softness abrasive flow based on Preston equation[J].Journal of Mechanical Engineering,2011,47(17):156-163.
[11]YIN S H,WANG Y,SHINMURA T.Material removal mechanism in vibration-assisted magnetic abrasive finishing[J].Advanced Materials Research,2008,53-54:57-63.
[2]计时鸣,唐波,谭大鹏,等.结构化表面软性磨粒流精密光整加工方法及其磨粒流动力学数值分析[J].机械工程学报,2010,46(15):178-184.JI Shiming,TANG Bo,TAN Dapeng,et al.Structural surface softness abrasive flow precision finish machining and its abrasive flow dynamic numerical analysis[J].Journal of Mechanical Engineering,2010,46(15):178-184.
[3]杨晓京,陈子辰,樊瑜瑾,等.磨粒磨损中微观切削过程分子动力学模拟[J].农业机械学报,2007,38(5):161-164.YANG Xiaojing,CHEN Zichen,FAN Yujin,et al.Molecular dynamics simulation of micro cutting process of abrasive wear[J].Transactions of the Chinese Society for Agricultural Machinery,2007,38(5):161-164.
[4]HASHISH M.A model for abrasive-waterjet(AWJ)machining[J].Journal of Engineering Materials and Technology ASME,1989,111(2):154-162.
[5]RAMULU M.Dynamic photoelastic investigation on themechanics of waterjet and abrasive waterjet machining[J].Optics and Lasers in Engineering,1993,19(1/3):43-65.
[6]JIA X,LING R F.Two-body free-abrasive wear of polyethylene,nylon1010,epoxy and polyurethane coatings[J].Tribology International,2007,40(8):1276-1283.
[7]LUíS M P,PIERPAOLO C,RENéV A O.Numerical study of the near-wall behavior of particles in turbulent pipe flows[J].Powder Technology,2002,125(2-3):149-157.
[8]HREIZ R,GENTRIC C,MIDOUX N.Numerical investigation of swirling flow in cylindrical cyclones[J].Chemical Engineering Research&Design,2012,88(12A):2521-2539.
[9]杨敏官,顾海飞,刘栋,等.离心泵叶轮内部湍流流动的数值计算及试验[J].机械工程学报,2006,42(12):180-185.YANG Minguan,GU Haifei,LIU Dong,et al.Numerical simulation and experiment study for turbulent flow in the impeller of centrifugal pump[J].Chinese Journal of Mechanical Engineering,2006,42(12):180-185.
[10]计时鸣,李琛,谭大鹏,等.基于Preston方程的软性磨粒流加工特性[J].机械工程学报,2011,47(17):156-163.JI Shiming,LI Chen,TAN Dapeng,et al.Study on machinability of softness abrasive flow based on Preston equation[J].Journal of Mechanical Engineering,2011,47(17):156-163.
[11]YIN S H,WANG Y,SHINMURA T.Material removal mechanism in vibration-assisted magnetic abrasive finishing[J].Advanced Materials Research,2008,53-54:57-63.