单层磨料砂轮修整及修整阈值控制试验研究
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摘要
针对粗粒度超硬磨料砂轮圆跳动难以检测技术问题,提出一种新的砂轮圆跳动检测方法,利用滑块组件与激光位移传感器有机结合,避免了砂轮表面高硬度磨料和粗糙形貌对传统量仪触头的机械干扰,排除了砂轮表面非均质材料及高陡坡磨粒的光学干扰,可实现粗粒度超硬磨料砂轮圆跳动的真实、稳定、高效、高精检测。在CNC8325数控外圆磨床上对粒度60#/70#电镀CBN砂轮进行了精密修整试验,依据"定量修整-砂轮检测-定量磨削-试件检测"循环测试方案,持续跟踪了电镀CBN砂轮圆跳动、磨削功率、试件表面质量、砂轮表面形貌渐变过程。结果表明:当电镀CBN砂轮初始圆跳动在10~20μm时,砂轮已具有良好的综合磨削效果,可以不修整或微量修整;当砂轮表面高点区域部分磨粒去除量在磨料平均直径1/5以内时,仍可通过精密修整获取理想的砂轮表面;当砂轮表面高点区域部分磨粒去除量达1/4以上时,即使修整后砂轮圆跳动很好,也无法获得较好磨削效果,此时砂轮已不具备磨削能力。
Aiming at the difficulties in detecting radial circular run-out error of coarse-grained super-abrasive wheels, a new detection method for wheels' circular run-out error is proposed, which is based on the organic combination of a slider component and a laser displacement sensor. This method can remove mechanical disturbances on the probes of traditional instruments from high hardness abrasive and rough surface topography of wheels, and avoid optical interference on the laser sensor from heterogeneous material and steep slope grains on the wheels' surface, which help realize the actual, stability, high efficiency, high precision detection for radial circular run-out error of coarse-grained super-abrasive wheels. A precision dressing experiment, aimed at electroplated CBN wheel whose grain size is 60/70, is carried out on CNC cylindrical grinding machine. This experiment adopted the cycle test program of quantitative dressing, wheel measurement, regular grinding, and specimen workpiece inspection, at the same time, the whole changes process of the wheel run-out error, grinding power, grinding surface quality, and wheel surface topography, are kept on track. The results showed that, the electroplated CBN grinding wheel has a good overall grinding effect, which makes wheel require little or no dress, when the initial run-out error of wheel is about 10-20 μm; when the maximum removal amount of the abrasive wheel surface highest area grains is within 1/5 of grains average diameter, the desired grinding wheel surface can be obtained by precise dressing; when the maximum removal amount of the abrasive wheel surface highest area grains is within 1/4 of grains average diameter, the better grinding effect cannot be achieved even the dressed wheel run-out error is well, which has no more grinding ability.
Aiming at the difficulties in detecting radial circular run-out error of coarse-grained super-abrasive wheels, a new detection method for wheels' circular run-out error is proposed, which is based on the organic combination of a slider component and a laser displacement sensor. This method can remove mechanical disturbances on the probes of traditional instruments from high hardness abrasive and rough surface topography of wheels, and avoid optical interference on the laser sensor from heterogeneous material and steep slope grains on the wheels' surface, which help realize the actual, stability, high efficiency, high precision detection for radial circular run-out error of coarse-grained super-abrasive wheels. A precision dressing experiment, aimed at electroplated CBN wheel whose grain size is 60/70, is carried out on CNC cylindrical grinding machine. This experiment adopted the cycle test program of quantitative dressing, wheel measurement, regular grinding, and specimen workpiece inspection, at the same time, the whole changes process of the wheel run-out error, grinding power, grinding surface quality, and wheel surface topography, are kept on track. The results showed that, the electroplated CBN grinding wheel has a good overall grinding effect, which makes wheel require little or no dress, when the initial run-out error of wheel is about 10-20 μm; when the maximum removal amount of the abrasive wheel surface highest area grains is within 1/5 of grains average diameter, the desired grinding wheel surface can be obtained by precise dressing; when the maximum removal amount of the abrasive wheel surface highest area grains is within 1/4 of grains average diameter, the better grinding effect cannot be achieved even the dressed wheel run-out error is well, which has no more grinding ability.
引文
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[14]朱建辉,闫宁,冯克明,等.电镀砂轮径跳检测方法和磨削试验研究[J].机械设计与制造,2015,298(12):122-124.ZHU Jianhui,YAN Ning,FENG Keming,et al.Electroplated grinding wheel radial runout and its influences on grinding performance[J].Machinery Design&Manufacture,2015,298(12):122-124.
[15]LIN X H,WANG Z Z,GUO Y B,et al.Research on the error analysis and compensation for the precision grinding of large aspheric mirror surface[J].The International Journal of Advanced Manufacturing Technology,2014,71(1-4):233-239.
[16]WEINGARTNER E,ROUTH R,KUSTER F.Electrical discharge dressing and its influence on metal bonded diamond wheels[J].CIRP Annals Manufacturing Technology,2012,61(1):183-186.
[2]庄司克雄.磨削加工技术[M].郭隐彪,译.北京:机械工业出版社,2007.SYOJI K.Grinding technology[M].Translated by GUO Yinbiao.Beijing:China Machine Press,2007.
[3]LI Shusheng,XU Jiuhua,XIAO Bing,et al.Performance of brazed diamond cup-type wheels with defined grain pattern in grinding cemented carbide[J].Transactions of Nanjing University of Aeronautic&Astronautics,2007,24(1):54-58.
[4]HEINZCL C,RICKENS K.Engineered wheels for grinding of optical glass[J].CIRP-Manufacturing Technology,2009,58(1):315-318.
[5]CHEN Jianyi,SHEN Jianyun,HUANG Hui,et al.Grinding characteristics in high speed grinding of engineering ceramics with brazed diamond wheels[J].Journal of Materials Processing Technology,2010,210(6-7):899-906.
[6]SU H H,FU Y C,XU J H,et al.Dressing of monolayer brazed diamond wheel for grinding Li-Ti ferrite[J].Advanced Materials Research,2010,126-128:995-1000.
[7]MIAO Q,DING W F,XU J H,et al.Fractal analysis of wear topography of brazed polycrystalline CBN abrasive grains during grinding nickel super alloy[J].International Journal of Advanced Manufacturing Technology,2013,68(9-12):2229-2236.
[8]崔仲鸣,郝青山,冯创举,等.超硬磨料磨具修整技术研究[J].金刚石与磨料磨具工程,2016,36(1):43-49.CUI Zhongming,HAO Qingshan,FENG Chuangju,et al.Study on dressing technology of super abrasive products[J].Diamond&Abrasives Engineering,2016,36(1):43-49.
[9]赵清亮,赵玲玲,王宇,等.电镀金刚石砂轮高效精密修整及熔融石英磨削试验研究[J].机械工程学报,2013,49(23):176-181.ZHAO Qingliang,ZHAO Lingling,WANG Yu,et al.High efficient precision conditioning of the electroplated diamond wheel and grinding of fused silica glasses[J].Journal of Mechanical Engineering,2013,49(23):176-181.
[10]刘佳,陈五一.电镀CBN砂轮油石修整效果及评价研究[J].金刚石与磨料磨具工程,2012,32(1):42-45.LIU Jia,CHEN Wuyi.Research on dressing effect and evaluation of electroplated CBN wheel with corundum dressing block[J].Diamond&Abrasives Engineering,2012,32(1):42-45.
[11]姜夏婷.电解修整单层钎焊金刚石砂轮的实验研究[J].金刚石磨料磨具工程,2013,33(4):23-27.JIANG Xiating.Experiment research on electrolytic dressing monolayer brazing diamond grinding[J].Diamond&Abrasives Engineering,2013,33(4):23-27.
[12]GHOSH A,CHATTOPADHYAY A K.Experimental investigation on performance of touch-dressed single-layer brazed CBN wheels[J].International Journal of Machine Tools&Manufacture,2007,47(7-8):1206-1213.
[13]徐旺,苏宏华,徐九华,等.碟轮修整单层钎焊金刚石砂轮的试验研究[J].金刚石磨料磨具工程,2012,32(1):38-41.XU Wang,SU Honghua,XU Jiuhua,et al.Experimental research on dressing of monolayer brazed diamond grinding wheel with plate wheel[J].Diamond&Abrasives Engineering,2012,32(1):38-41.
[14]朱建辉,闫宁,冯克明,等.电镀砂轮径跳检测方法和磨削试验研究[J].机械设计与制造,2015,298(12):122-124.ZHU Jianhui,YAN Ning,FENG Keming,et al.Electroplated grinding wheel radial runout and its influences on grinding performance[J].Machinery Design&Manufacture,2015,298(12):122-124.
[15]LIN X H,WANG Z Z,GUO Y B,et al.Research on the error analysis and compensation for the precision grinding of large aspheric mirror surface[J].The International Journal of Advanced Manufacturing Technology,2014,71(1-4):233-239.
[16]WEINGARTNER E,ROUTH R,KUSTER F.Electrical discharge dressing and its influence on metal bonded diamond wheels[J].CIRP Annals Manufacturing Technology,2012,61(1):183-186.