超声复合磁力研磨加工镍基合金GH4169异形管
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摘要
为解决镍基合金GH4169异型管内壁难研磨及研磨不均匀问题,采用超声复合磁力研磨光整加工方法进行试验。分析在超声复合磁力研磨条件下,主轴转速、加工间隙、超声频率和超声振幅对异形管内壁表面质量的影响。结果表明:在超声轴向频率为19 kHz、振幅19μm,主轴转速1000 r/min,磁性磨粒平均粒径250μm,加工间隙2 mm加工条件下,加工30 min后,管件内壁表面粗糙度Ra由原始的2.4μm降至0.31μm。通过在管件内部添加圆柱形辅助磁极,使得内外两磁极形成闭合磁场回路,增加磁场力的作用。辅助磁极连接高频轴向超声振动,使得吸附在磁极上的磁性磨粒在旋转运动和轴向高频振动复合作用下划擦、研磨管件内表面。由于研磨轨迹发生交叉复杂化,使得异型管内壁研磨后的表面质量和表面粗糙度得到明显提高;管件内壁表面残余应力由拉应力+52 MPa转变为压应力-48 MPa,表面应力状态得到较好的改善。
This investigation aims to solve the problem of difficult and uneven grinding by using ultrasonic assisted magnetic abrasive finishing(UAMAF) in the nickel-based alloy GH4169 with tube shaped inner wall.The effects of spindle speed,machining gap,ultrasonic frequency and ultrasonic amplitude on the surface quality of the special-shaped tube inner wall were analyzed under the condition of UAMAF.The test was carried out under the processing conditions of ultrasonic axial frequency of 19 μm,an amplitude of 19 μm an spindle speed of 1000 r/min,an average particle size of 250 μm of magnetic abrasive grain,and 2 mm machining gap.Results show that after 30 minutes of processing,the surface roughness of the inner wall of the pipe was reduced from the original Ra 2.4 μm to Ra 0.31 μm.Addition of a cylindrical auxiliary magnetic pole inside the pipe fitting causes the inner and outer magnetic poles form a closed magnetic field loop thereby increasing the magnetic field force.The vibration from the auxiliary magnetic pole is connected with the high-frequency axial ultrasonic vibration.It causes the magnetic abrasive particle adsorbed on the magnetic pole scratch to grind the inner surface of the pipe under the combined action of the rotary motion and the axial high-frequency vibration.Due to the cross-complication of the grinding trajectory,the surface quality and surface roughness of the inner wall of the tube are significantly improved.The residual stress on the inner wall surface of the pipe changes from tensile stress of +52 MPa to compressive stress of-48 MPa,and the surface stress state is improved.
This investigation aims to solve the problem of difficult and uneven grinding by using ultrasonic assisted magnetic abrasive finishing(UAMAF) in the nickel-based alloy GH4169 with tube shaped inner wall.The effects of spindle speed,machining gap,ultrasonic frequency and ultrasonic amplitude on the surface quality of the special-shaped tube inner wall were analyzed under the condition of UAMAF.The test was carried out under the processing conditions of ultrasonic axial frequency of 19 μm,an amplitude of 19 μm an spindle speed of 1000 r/min,an average particle size of 250 μm of magnetic abrasive grain,and 2 mm machining gap.Results show that after 30 minutes of processing,the surface roughness of the inner wall of the pipe was reduced from the original Ra 2.4 μm to Ra 0.31 μm.Addition of a cylindrical auxiliary magnetic pole inside the pipe fitting causes the inner and outer magnetic poles form a closed magnetic field loop thereby increasing the magnetic field force.The vibration from the auxiliary magnetic pole is connected with the high-frequency axial ultrasonic vibration.It causes the magnetic abrasive particle adsorbed on the magnetic pole scratch to grind the inner surface of the pipe under the combined action of the rotary motion and the axial high-frequency vibration.Due to the cross-complication of the grinding trajectory,the surface quality and surface roughness of the inner wall of the tube are significantly improved.The residual stress on the inner wall surface of the pipe changes from tensile stress of +52 MPa to compressive stress of-48 MPa,and the surface stress state is improved.
引文
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[15]杨海吉,张晓君,陈燕,等.磁力研磨精密抛光4×150 mm TC4管内表面的实验研究[J].表面技术,2017,46(12):259-264.YANG H J,ZANG X J,CHEN Y,et al.Polishing of inner surface ofφ4×150 mm TC4 tube by magnetic abrasive finishing,[J].Surface Technology,2017,46(12):259-264(in Chinese).
[16]朱磊,吴志荣,胡绪腾,等.镍基合金GH4169疲劳小裂纹的扩展行为[J].航空动力学报,2017,32(8):1984-1991.ZHU L,WU Z R,HU X T,et al.Small fatigue crack growth behavior of nickel-based alloy GH4169[J].Journal of Aeronautics and Dynamics,2017,32(8):1984-1991(in Chinese).
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[18]焦安源,全洪军,陈燕,等.超声磁力复合研磨钛合金锥孔的试验研究[J].机械工程学报,2017,53(19):114-119.JIAO A Y,QUAN H J,CHEN Y,et al.Experimental research of titanium alloy taper hole by ultrasonic magnetic abrasive finishing[J].Chinese Journal of Mechanical Engineering,2017,53(19):114-119(in Chinese).
[19]KONG Y H,LIU R Y,CHEN G S,et al.Effects of different heat treatments on the microstructures and creep properties of GH4169 superalloy[J].Journal of Materials Engineering and Performance,2013,22(5):1371-1377.
[20]廖明.电化学磁力研磨复合加工钛合金试验研究[D].鞍山:辽宁科技大学,2016.LIAO Ming.Research abrasive on the electrochemical magnetic finishing of titanium alloy[D].Anshan:University of Science and Technology Liaoning,2016(in Chinese).
[21]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 M,HAN B,CHEN Y,et al.Inner surface of titanium alloy tube by eletrochemical magnetic abrasive compound finishing[J].China Surface Engineering,2016,29(3):123-131(in Chinese).
[2]姚进军,高联科,邓斌.镍基高温合金的技术进展[J].新材料产业,2015,16(12):43-46.YAO J J,GAO L K,DENG B.Technical progress of nickel base superalloy[J].New Material Industry,2015,16(12):43-46(in Chinese).
[3]ADIB A M L,BAPTISTA C A R P,BARBOZA M J R,et al.Air craft engine bleed system tubes:material and failure mode analysis[J].Engineering Failure Analysis,2007,14(8):1605-1617.
[4]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 E H,WANG J Q,WU X Q,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(in Chinese).
[5]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 D,ZHANG Y Q,LEI W G,et al.Development of manufacturing technology and application for nickel alloys sheets and strips[J].Material Guide,2015,29(5):83-87(in Chinese).
[6]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 H J,HAN B,CHEN Y,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(in Chinese).
[7]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.
[8]周金保.镍基耐蚀合金的表面处理[J].电镀与精饰,1998,25(3):24-26.ZHOU J B.Nickel base corrosion resistant alloy surface treatment[J].Plating and Finishing,1998,25(3):24-26(in Chinese).
[9]白阿香,魏刚,乔宁.表面处理对镍基合金加热管腐蚀行为的影响[J].腐蚀科学与防护技术,2012,24(3):228-231.BAI A X,WEI G,QIAO N.Influnce of surface treatments on corrosion performance of ni-based alloys for heating tube[J].Corrosion Science and Protection Technology,2012,24(3):228-231(in Chinese).
[10]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 B,DENG C,CHEN Y.The spherical magnet processing of inner surface of bending pipe by magnetic abrasive finishing[J].Journal of Tribology,2013,33(6):565-570(in Chinese).
[11]郭龙文,杨能阁,陈燕.磁力研磨工艺对整体叶盘表面完整性的影响[J].中国表面工程,2013,26(3):10-14.GUO L W,YANG N G,CHEN Y.Influence of magnetic abrasive finishing technology on surface integrity of vane-integrated disk[J].China Surface Engineering,2013,26(3):10-14(in Chinese).
[12]KANG J,YAMAGUCH H.Internal finishing of capillary tubes by magnetic abrasive finishing using a multiple poletip system[J].Precision Engineering,2012,36(3):510-516.
[13]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 Y,SONG Z P,LI C,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(in Chinese).
[14]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,2015,472(3):61-63.DENG C,HAN B,CHEN Y.Study of inner surface polishing of titanium alloy elbow pipe by magnetic abrasive finishing[J].Aviation Manufacturing Technology,2015,472(3):61-63(in Chinese).
[15]杨海吉,张晓君,陈燕,等.磁力研磨精密抛光4×150 mm TC4管内表面的实验研究[J].表面技术,2017,46(12):259-264.YANG H J,ZANG X J,CHEN Y,et al.Polishing of inner surface ofφ4×150 mm TC4 tube by magnetic abrasive finishing,[J].Surface Technology,2017,46(12):259-264(in Chinese).
[16]朱磊,吴志荣,胡绪腾,等.镍基合金GH4169疲劳小裂纹的扩展行为[J].航空动力学报,2017,32(8):1984-1991.ZHU L,WU Z R,HU X T,et al.Small fatigue crack growth behavior of nickel-based alloy GH4169[J].Journal of Aeronautics and Dynamics,2017,32(8):1984-1991(in Chinese).
[17]LIU Z Q CHEN Y,LI Y J,et al.Comprehensive performance evaluation of the magnetic abrasive particles[J].The International Journal of Advanced Manufacturing Technology,2013,68(1-4):631-640.
[18]焦安源,全洪军,陈燕,等.超声磁力复合研磨钛合金锥孔的试验研究[J].机械工程学报,2017,53(19):114-119.JIAO A Y,QUAN H J,CHEN Y,et al.Experimental research of titanium alloy taper hole by ultrasonic magnetic abrasive finishing[J].Chinese Journal of Mechanical Engineering,2017,53(19):114-119(in Chinese).
[19]KONG Y H,LIU R Y,CHEN G S,et al.Effects of different heat treatments on the microstructures and creep properties of GH4169 superalloy[J].Journal of Materials Engineering and Performance,2013,22(5):1371-1377.
[20]廖明.电化学磁力研磨复合加工钛合金试验研究[D].鞍山:辽宁科技大学,2016.LIAO Ming.Research abrasive on the electrochemical magnetic finishing of titanium alloy[D].Anshan:University of Science and Technology Liaoning,2016(in Chinese).
[21]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 M,HAN B,CHEN Y,et al.Inner surface of titanium alloy tube by eletrochemical magnetic abrasive compound finishing[J].China Surface Engineering,2016,29(3):123-131(in Chinese).