超声复合磁力研磨异型管参数优化设计及分析
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摘要
目的改善镍基合金异型管表面质量,降低表面粗糙度。方法在内置辅助磁极磁力研磨基础上添加轴向超声振动,促使磁力研磨粒子对管件内表面进行轴向划擦、刻划作用。采用响应面法对试验进行3因素3水平方法设计,建立参数优化三维数学模型,分析超声频率、超声振幅、主轴转速在两因素交互作用下,对异型管内壁表面质量、表面粗糙度的影响,并得出试验最佳参数组合。结果响应面法优化设计在超声频率19 kHz、超声振幅19μm、主轴转速1200 r/min条件下的加工效果最佳。在优化工艺参数下进行超声复合磁力研磨试验,加工30 min后,管件内壁表面粗糙度由原始2.4μm降至0.31μm,管件内表面残余拉应力由+49MPa转变为残余压应力?47MPa。结论在内置辅助磁极磁力研磨基础上添加超声轴向振动,使得研磨粒子翻滚加剧,研磨轨迹复杂化,有效改善了管件内壁表面粗糙度和表面加工质量。响应面法能够对试验结果进行优化参数数学建模设计,拟合出了最佳的加工参数组合,良好的应力状态有效地提高了工件的疲劳强度。
The work aims to improve the surface quality of nickel based alloy special-shaped tubes and reduce the surface roughness by machining the nickel based alloy special-shaped tubes with ultrasonic combined magnetic abrasive finishing and investigate the effects of ultrasonic frequency, ultrasonic amplitude and spindle speed on the inner wall surface quality and surface roughness of special-shaped tubes by response surface methodology. The axial ultrasonic vibration was added on the basis of the built-in auxiliary magnetic pole magnetic abrasive to promote the magnetic abrasive particles to scratch and carve the inner surface of the tube. The response surface method was used to design the 3-factor and 3-level method, and the three-dimensional mathematical model was set up to analyze the effects of ultrasonic frequency, ultrasonic amplitude and spindle speed on the surface quality and surface roughness of the inner wall of the special-shaped tube under two factors to obtain the best combination of parameters. The optimum design of response surface method was the best in the condition of ultrasonic frequency 19 kHz, ultrasonic amplitude 19 μm and spindle speed 1200 r/min. Under the optimized process parameters, the ultrasonic composite magnetic grinding test was carried out. After 30 min processing, the surface roughness of the inner wall of the pipe was reduced from original Ra 2.4 μm to Ra 0.31 μm. The residual tensile stress +49 MPa of tube was changed to residual compressive stress ?47 MPa. The ultrasonic axial vibration is added on the basis of the auxiliary magnetic pole magnetic grinding, which makes the grinding particle roll up and the grinding track complicated and effectively improves the surface roughness of the inner wall of the pipe and the surface processing quality. The response surface method can optimize the mathematical modeling design of the test results and fit the best combination of the processing parameters. The good stress state effectively improves the fatigue strength of the workpiece.
The work aims to improve the surface quality of nickel based alloy special-shaped tubes and reduce the surface roughness by machining the nickel based alloy special-shaped tubes with ultrasonic combined magnetic abrasive finishing and investigate the effects of ultrasonic frequency, ultrasonic amplitude and spindle speed on the inner wall surface quality and surface roughness of special-shaped tubes by response surface methodology. The axial ultrasonic vibration was added on the basis of the built-in auxiliary magnetic pole magnetic abrasive to promote the magnetic abrasive particles to scratch and carve the inner surface of the tube. The response surface method was used to design the 3-factor and 3-level method, and the three-dimensional mathematical model was set up to analyze the effects of ultrasonic frequency, ultrasonic amplitude and spindle speed on the surface quality and surface roughness of the inner wall of the special-shaped tube under two factors to obtain the best combination of parameters. The optimum design of response surface method was the best in the condition of ultrasonic frequency 19 kHz, ultrasonic amplitude 19 μm and spindle speed 1200 r/min. Under the optimized process parameters, the ultrasonic composite magnetic grinding test was carried out. After 30 min processing, the surface roughness of the inner wall of the pipe was reduced from original Ra 2.4 μm to Ra 0.31 μm. The residual tensile stress +49 MPa of tube was changed to residual compressive stress ?47 MPa. The ultrasonic axial vibration is added on the basis of the auxiliary magnetic pole magnetic grinding, which makes the grinding particle roll up and the grinding track complicated and effectively improves the surface roughness of the inner wall of the pipe and the surface processing quality. The response surface method can optimize the mathematical modeling design of the test results and fit the best combination of the processing parameters. The good stress state effectively improves the fatigue strength of the workpiece.
引文
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[18]廖明,韩冰,陈燕,等.钛合金管内表面的电化学磁力研磨复合光整试验[J].中国表面工程,2016,29(3):123-131.LIAO Ming,HAN Bing,CHEN Yan,et al.Inner surface of titanium alloy tube by eletrochemical magnetic abrasive compound finishing[J].China surface engineering,2016,29(3):123-131.
[2]王庆仓,张晓东,苏建修,等.SiC单晶片化学机械研磨试验研究[J].表面技术,2015,44(4):137-140.WANG Qing-cang,ZHANG Xiao-dong,SU Jian-xiu,et al.Experimental study on chemical mechanical lapping of Si C single crystal wafer[J].Surface technology,2015,44(4):137-140.
[3]韩恩厚,王俭秋,吴欣强,等.核电高温高压水中不锈钢和镍基合金的腐蚀机制[J].金属学报,2010,46(11):1379-1390.HAN En-hou,WANG Jian-qiu,WU Xin-qiang,et al.Corrosion mechanism of stainless steel and nickel based alloys in high temperature high pressure water[J].Acta metals sinica,2010,46(11):1379-1390.
[4]韩栋,张永强,雷文光,等.镍基合金板带加工技术及应用发展现状[J].材料导报,2015,29(5):83-87.HAN Dong,ZHANG Yong-qiang,LEI Wen-guang,et al.Development of manufacturing technology and application for nickel alloys sheets and strips[J].Material guide,2015,29(5):83-87.
[5]庞继明,肖雅静,曲恒磊,等.不同方法制备的钦及钦合金管坯组织与性能研究[J].钦工业进展,2010,27(4):34-36.PANG Ji-ming,XIAO Ya-jing,QU Heng-lei,et al.Study on microstructure and properties of titanium and titanium alloy tube blanks manufactured by different methods[J].Titanium industry progress,2010,27(4):34-36.
[6]江志强,杨合,詹梅,等.钦合金管材研制及其在航空领域应用的现状与前景[J].塑性工程学报,2009,16(4):44-50.JIANG Zhi-qiang,YANG He,ZHAN Mei,et al.State and prospective of manufacturing and application of titanium alloy tube in aviation industry[J].Journal of plasticity engineering,2009,16(4):44-50.
[7]韩冰,刘立鑫,陈燕.磁力研磨法加工弯管内表面的工艺参数优化[J].中国机械工程,2015,26(6):814-817.HAN Bing,LIU Li-xin,CHEN Yan.Optimization of process parameters on magnetic abrasive finishing to inner surface of bending pipe[J].Chinese mechanical engineering,2015,26(6):814-817.
[8]LIN C T,YANG L D,CHOW H M.Study of magnetic abrasive finishing in free-form surface operations using the Taguchi method[J].The international journal of advanced manufacturing technology,2007,34(1/2):122-130.
[9]韩冰,邓超,陈燕.球形磁铁在弯管内表面磁力研磨中的应用[J].摩擦学学报,2013,33(6):565-570.HAN Bin,DENG Chao,CHEN Yan.The spherical magnet processing of inner surface of bending pipe by magnetic abrasive finishing[J].Journal of tribology,2013,33(6):565-570.
[10]PAN J,YAN Q,XU X,et al.Abrasive particles trajectory analysis and simulation of cluster magnet orheological effect plane polishing[J].Physics procedia,2012,25(22):176-184.
[11]杨海吉,韩冰,陈燕,等.自旋转磁极在合金管内表面精密抛光中的应用[J].摩擦学学报,2018,38(2):189-195.YANG Hai-ji,HAN Bing,CHEN Yan,et al.The application of rotating magnetic pole in the polishing of the inner surface of the alloy tube[J].Journal of tribology,2018,38(2):189-195.
[12]陈燕,宋宗朋,李昌,等.磁研磨法抛光40Cr钢管件内表面的影响因素[J].中国表面工程,2015,28(4):62-69.CHEN Yan,SONG Zong-peng,LI Chang,et al.Influencing factors on polishing inner surface of 40Cr steel pipe fittings with a magnetic grinding method[J].China surface engineering,2015,28(4):62-69.
[13]LIU Z Q,CHEN Y,LI Y J.Comprehensive performance evaluation of the magnetic abrasive particles[J].The international journal of advanced manufacturing technology,2013,68(1-4):631-640.
[14]PEATEEK K,PULAK M P,GIRISH C V,et al.Understanding flexible abrasive brush behavior for double disk magnetic abrasive finishing based on force signature[J].Journal of manufacturing processes,2017.
[15]PEATEEK K,PULAK M P.Comparison of finishing characteristics of two paramagnetic materials using double disc magnetic abrasive finishing[J].Journal of manufacturing processes,2015,17(1):63-77.
[16]FERREIRA N G,ABRAMOF E,CORAT E J,et al.Residual stresses and crystalline quality of heavily boron-loped diamond films analysed by micro-Raman spectroscopy and X-ray diffraction[J].Carbon,2003,41(6):1301-1308.
[17]陈燕,宋宗朋,李昌,等.磁研磨法抛光40Cr钢管件内表面的影响因素[J].中国表面工程,2015,28(4):62-69.CHEN Yan,SONG Zong-peng,LI Chang,et al.Influencing factors on polishing inner surface of 40Cr steel pipe fittings with a magnetic grinding method[J].China surface engineering,2015,28(4):62-69.
[18]廖明,韩冰,陈燕,等.钛合金管内表面的电化学磁力研磨复合光整试验[J].中国表面工程,2016,29(3):123-131.LIAO Ming,HAN Bing,CHEN Yan,et al.Inner surface of titanium alloy tube by eletrochemical magnetic abrasive compound finishing[J].China surface engineering,2016,29(3):123-131.