基于3D打印航空发动机喷油管磁力研磨试验研究
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摘要
目的针对镍基合金GH4169航空发动机喷油管进行磁力研磨光整加工试验研究,分析内置辅助磁极磁力研磨对工件内表面及交叉孔相贯线去毛刺的效果。方法利用磁粒研磨内置辅助磁极光整加工对工件内表面及内交叉孔相贯线处进行磁力研磨加工,通过研磨粒子与工件之间的划擦、磨削等运动,提高工件表面质量和去除内交叉孔相贯线处的毛刺。结果磁轭转速为1000 r/min,加工间隙为6 mm,采用圆柱形辅助磁极及平均粒径为250μm的磁性磨料时,其加工效果比传统的加工效果好,且效率更高,工件表面粗糙度从原始的5.8μm降至0.47μm(Ra<0.5μm),内交叉孔相贯线处的毛刺明显被去除,且由于磁性研磨粒子的研磨作用,可对其进行二次光整加工。结论通过磁力研磨内置辅助磁极光整加工方法,原始工件内表面存在的褶皱、微裂纹明显得到改善,交叉孔相贯线处的毛刺也明显被去除。试验选用磁性研磨粒子粒径为250μm时,研磨效果最佳。通过磁力研磨光整加工后,管件能够得到良好的表面效果,提高了管件的综合性能。
Experimental research on magnetic abrasive finishing for GH4169 alloy fuel injector of nickel based alloy was carried out and analyze the deburring effect of the built-in auxiliary pole magnetic abrasive finishing on the inner surface of the workpiece and the cross hole line. The Aurora built-in auxiliary magnetic abrasive machining was used to grind and process the inner surface of workpiece and internal cross hole line. The movements like scratch, grinding, etc. between the abrasive particles and the workpiece were adopted to improve the quality of the workpiece surface and remove the cross hole line burr. The magnetic abrasive with yoke speed of 1000 r/min, cylindrical auxiliary pole, machining gap of 6 mm and average grain size of 250 μm could provide better machining effects and higher efficiency than the traditional processing. The surface roughness of the detected workpiece could drop to 0.47 μm from the original 5.8 μm(Ra<0.5 ?m). The burr at the internal cross hole line was obviously removed and the second finishing process could be conducted due to the abrasive action of magnetic particles. The built-in auxiliary pole magnetic abrasive finishing method can be adopted to improve the folds and minor cracks on the surface of the original workpiece and remove the burr at the cross hole line. When the particle size of the magnetic abrasive particle is 250 ?m, the grinding effect is the best. After finishing by magnetic abrasive finishing, the pipe can get good surface effect and improve the comprehensive performance of the pipe.
Experimental research on magnetic abrasive finishing for GH4169 alloy fuel injector of nickel based alloy was carried out and analyze the deburring effect of the built-in auxiliary pole magnetic abrasive finishing on the inner surface of the workpiece and the cross hole line. The Aurora built-in auxiliary magnetic abrasive machining was used to grind and process the inner surface of workpiece and internal cross hole line. The movements like scratch, grinding, etc. between the abrasive particles and the workpiece were adopted to improve the quality of the workpiece surface and remove the cross hole line burr. The magnetic abrasive with yoke speed of 1000 r/min, cylindrical auxiliary pole, machining gap of 6 mm and average grain size of 250 μm could provide better machining effects and higher efficiency than the traditional processing. The surface roughness of the detected workpiece could drop to 0.47 μm from the original 5.8 μm(Ra<0.5 ?m). The burr at the internal cross hole line was obviously removed and the second finishing process could be conducted due to the abrasive action of magnetic particles. The built-in auxiliary pole magnetic abrasive finishing method can be adopted to improve the folds and minor cracks on the surface of the original workpiece and remove the burr at the cross hole line. When the particle size of the magnetic abrasive particle is 250 ?m, the grinding effect is the best. After finishing by magnetic abrasive finishing, the pipe can get good surface effect and improve the comprehensive performance of the pipe.
引文
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[2]赵明,王兴林,金耀兴.复合加工技术在航空复杂零件加工中的应用[J].航空制造技术,2011(19):40-43.ZHAO Ming,WANG Xing-lin,JIN Yao-xing.Application of complex machining technology in aircraft complicated part[J].Aeronautical manufacturing technology,2011(19):40-43.
[3]谭悦,陈燕,曾加恒,等.电解-磁力复合研磨对TA18管内表面光整加工[J].电镀与涂饰,2017,36(5):248-252.TAN Yue,CHEN Yan,ZENG Jia-heng,et al.Finishing and machining of inner surface of TA18 pipe by electrolytic-magnetic composite grinding[J].Electroplating&finishing,2017,36(5):248-252.
[4]LIU G,HE N,MAN Z L,et al.Cutting forces in the milling of inconel718[J].Key engineering materials,2004,259/260:824-828.
[5]谭悦,陈燕,曾加恒,等.超声磁力复合研磨对TA18管内表面光整加工[J].电镀与涂饰,2017,36(16):870-873.TAN Yue,CHEN Yan,ZENG Jia-heng,et al.Finishing machining of inner surface of TA18 pipe by ultrasonic-magnetic composite grinding[J].Electroplating&finishing,2017,36(16):870-873.
[6]郭艳玲,朱勋鹏,李健,等.基于电化学法的内交叉阵列孔毛刺去除工艺[J].制造技术与机床,2014(7):101-105.GUO Yan-ling,ZHU Xun-peng,LI Jian,et al.Technology on ECM of deburring in internal crossed hole arrays[J].Manufacturing technology and machine tool,2014(7):101-105.
[7]吴凡,唐辉民,安岩.沉淀硬化不锈钢零件交叉孔精密磨削工艺研究[J].航空精密制造技术,2010,46(5):17-19.WU Fan,TANG Hui-min,AN Yan.Study on cross hole grinding technology for precip itation stainless steel[J].Aviation precision manufacturing technology,2010,46(5):17-19.
[8]李健,王振龙,郭艳玲.自动化电解去内交叉孔毛刺过程的仿真与实验[J].哈尔滨工业大学学报,2016,48(1):152-158.LI Jian,WANG Zhen-long,GUO Yan-ling.Simulation and experiment of automatic electrolytic deburringoninner intersecting holes based on electric current detection[J].Journal of Harbin Institute of Technology,2016,48(1):152-158.
[9]陈燕,张耀明,邓超,等.V形磁铁在SUS304管内表面抛光中的应用[J].机械工程学报,2014(15):187-191.CHEN Yan,ZHANG Yao-ming,DENG Chao,et al.Application of V-shaped magnet in polishing the inner surface of the SUS304 tubing[J].Proceedings of the Chinese academy of mechanical engineering,2014(15):187-191.
[10]杜兆伟,陈燕,周锟,等.磁力研磨法对整体叶盘的抛光工艺研究[J].航空制造技术,2015(20):93-95.DU Zhao-wei,CHEN Yan,ZHOU Kun,et al.Study on blisk surface polishing by magnetic abrasive finishing[J].Aeronautical manufacturing technology,2015(20):93-95.
[11]肖阳,孙友松,陈光忠.永磁场磁力研磨TC11钛合金的实验研究[J].表面技术,2017,46(2):229-234.XIAO Yang,SUN You-song,CHEN Guang-zhong.Experimental study of magnetic abrasive finishing of TC11titanium alloy in permanent magnetic field[J].Surface technology,2017,46(2):229-234.
[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]邓超,韩冰,陈燕.磁研磨法对钛合金弯管内表面的抛光研究[J].航空制造技术,2015(3):61-63.DENG Chao,HAN Bing,CHEN Yan.Study of inner surface polishing of titanium alloy elbow pipe by magnetic abrasive finishing[J].Aviation manufacturing technology,2015(3):61-63.
[14]杨海吉,张晓君,陈燕,等.磁力研磨精密抛光?4×150mm TC4管内表面的实验研究[J].表面技术,2017(12):259-264.YANG Hai-ji,ZANG Xiao-jun,CHEN Yan,et al.Polishing of inner surface of?4×150 mm tc4 tube by magnetic abrasive finishing[J].Surface technology,2017(12):259-264.
[15]ZOU Y H,AKUTSU S,SHINURA T.Development of a new ultra-precision magnetic abrasive finishing process[J].Journal of the Japan society for abrasive technology,2010,54(2):97-100.
[16]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 Bing,DENG Chao,CHEN Yan.The spherical magnet processing of inner surface of bending pipe by magnetic abrasive finishing[J].Tribology,2013,33(6):565-570.