磁性磨粒辅助磁针磁力研磨的应用研究
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摘要
目的解决磁针磁力研磨工艺中磁针对工件表面碰撞损伤及存在研磨盲区的问题。方法在磁针中加入磁性磨粒增加磁针束的柔性,同时磁针为磁性磨粒提供研磨压力和切削力。将三相正弦交流电接入定子线圈,利用交流电的相位差产生旋转磁场,驱动混合磨料对微小复杂工件进行研磨。在混合磨料总质量不变的条件下,依次采用磁针、磁性磨粒和不同质量混合比的混合磨料进行对比试验。结果相较于单一磨料,使用混合磨料加工40 min后的工件表面形貌较好,表面粗糙度值下降幅度大,且有较大的材料去除量。当磁针与磁性磨粒的质量混合比为1∶2时,加工后的工件表面形貌最佳,无明显加工纹理和磁针碰撞痕迹,工件表面粗糙度值由原始的1.0μm下降到0.54μm左右,材料去除量为2.8 mg左右,微小沟槽内无研磨盲区。结论在电磁研磨工艺中,使用磁针和磁性磨粒质量比为1∶2的混合磨料可提高研磨效果,避免磁针的碰撞对工件表面造成损伤,磁针可将磁性磨粒挤入工件微小沟槽,无研磨盲区。
The work aims to solve the problems of collision damage and blind sector in magnetic needle magnetic grinding process. Magnetic abrasive particles were added to increase the flexibility of the magnetic needles. At the same time, the magnetic needle provided grinding pressure and cutting force for the magnetic abrasive particles. The three-phase sinusoidal alternating current was connected to the stator coil, and the phase difference of the alternating current was used to generate a rotating magnetic field to drive the mixed abrasive to grind the tiny and complicated workpieces. Under the condition that the total mass of the mixed abrasive was unchanged, the magnetic needles, the magnetic abrasive particles and the mixed abrasive with different mass mixing ratios were sequentially used to carry out comparative experiments. Compared with single abrasive, the workpiece surface morphology after 40 min of processing with mixed abrasive was better. The surface roughness value decreased greatly, and there was a larger amount of material removed. When the mass mixing ratio of the magnetic needle and the magnetic abrasive particles was 1∶2, the surface morphology of the processed workpiece was the best, and there was no obvious processing texture or magnetic needle collision trace. The surface roughness of the workpiece decreased from the original Ra 1.0 μm to Ra 0.54 μm. The material removal amount was about 2.8 mg. There was no grinding dead angle in the micro groove. In the electromagnetic grinding process, the use of a mixed abrasive of magnetic needles and magnetic abrasive particles with a mass mixing ratio of 1∶2 can improve the grinding effect and prevent the surface of the workpiece from being damaged by the collision of the magnetic needles. The magnetic needle can squeeze magnetic abrasive particles into narrow grooves of the workpiece without grinding blind areas.
The work aims to solve the problems of collision damage and blind sector in magnetic needle magnetic grinding process. Magnetic abrasive particles were added to increase the flexibility of the magnetic needles. At the same time, the magnetic needle provided grinding pressure and cutting force for the magnetic abrasive particles. The three-phase sinusoidal alternating current was connected to the stator coil, and the phase difference of the alternating current was used to generate a rotating magnetic field to drive the mixed abrasive to grind the tiny and complicated workpieces. Under the condition that the total mass of the mixed abrasive was unchanged, the magnetic needles, the magnetic abrasive particles and the mixed abrasive with different mass mixing ratios were sequentially used to carry out comparative experiments. Compared with single abrasive, the workpiece surface morphology after 40 min of processing with mixed abrasive was better. The surface roughness value decreased greatly, and there was a larger amount of material removed. When the mass mixing ratio of the magnetic needle and the magnetic abrasive particles was 1∶2, the surface morphology of the processed workpiece was the best, and there was no obvious processing texture or magnetic needle collision trace. The surface roughness of the workpiece decreased from the original Ra 1.0 μm to Ra 0.54 μm. The material removal amount was about 2.8 mg. There was no grinding dead angle in the micro groove. In the electromagnetic grinding process, the use of a mixed abrasive of magnetic needles and magnetic abrasive particles with a mass mixing ratio of 1∶2 can improve the grinding effect and prevent the surface of the workpiece from being damaged by the collision of the magnetic needles. The magnetic needle can squeeze magnetic abrasive particles into narrow grooves of the workpiece without grinding blind areas.
引文
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[16]杨海涛,张清林,陈大陆.柴油机喷嘴喷孔表面微观形貌测量及应用[J].表面技术,2017,46(12):283-289.YANG Hai-tao,ZHANG Qing-lin,CHEN Da-lu.Surface microstructure measurement and application of diesel engine nozzle holes[J].Surface technology,2017,46(12):283-289.
[2]GUPTA K,JAIN N K,LAUBSCHER R F.Assisted hybrid machining processes[J].Springer briefs in applied sciences&technology,2016,236:45-65.
[3]DEBNATH S,KUNAR S,ANASANE S S,et al.Nontraditional micromachining processes:Opportunities and challenges[M].Heidelberg:Springer International Publishing,2017.
[4]孙岩,兰勇,陈燕.磁性和非磁性材料微小沟槽表面的磁力研磨光整加工[J].制造技术与机床,2015(9):132-136.SUN Yan,LAN Yong,CHEN Yan.The finishing machining of tiny groove surface of magnetic and non-magnetic materia by magnetic abrasive finishing[J].Manufacturing technology&machine tool,2015(9):132-136.
[5]宋庆环.磁研磨法应用于模具型腔的光整加工[J].机械设计与制造,2009(2):248-250.SONG Qing-huan.Magnetic grinding method applied in complex cavity finishing[J].Machinery design&manufacture,2009(2):248-250.
[6]李阔,陈燕,张志超,等.利用交变旋转磁场去除叶片气膜孔毛刺的试验研究[J].航空制造技术,2017(9):66-70.LI Kuo,CHEN Yan,ZHANG Zhi-chao,et al.Experimental study on film cooling hole de-burring by alternating rotating magnetic field[J].Aeronautical manufacturing technology,2017(9):66-70.
[7]AMNIEH S K,MOSADDEGH P,TEHRANI A F.Study on magnetic abrasive finishing of spiral grooves inside of aluminum cylinders[J].International journal of advanced manufacturing technology,2017,91(5):1-10.
[8]KAJAL S,JAIN V K,RAMKUMAR J,et al.Experimental and theoretical investigations into internal magnetic abrasive finishing of a revolver barrel[J].International journal of advanced manufacturing technology,2017,56:1-18.
[9]李彦俊,陈燕,郭龙文.磁研磨法去除微小喷嘴棱边处毛刺的研究[J].航空制造技术,2014,453(9):88-90.LI Yan-jun,CHEN Yan,GUO Long-wen.Study of de-burring on edge of micro nozzle by magnetic abrasive finishing[J].Aeronautical manufacturing technology,2014,453(9):88-90.
[10]高建红.钛合金滚磨光整加工表面完整性研究[D].太原:太原理工大学,2014:18-22.GAO Jian-hong.Study of surface integrity of titanium alloy with barrel finishing technology[D].Taiyuan:Taiyuan University of Technology,2014:18-22.
[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].Tribology,2018,38(2):189-195.
[12]VERMA G C,KALA P,PANDEY P M.Experimental investigations into internal magnetic abrasive finishing of pipes[J].International journal of advanced manufacturing technology,2016,88(5-8):1-12.
[13]ZHOU K,CHEN Y,DU Z W,et al.Surface integrity of titanium part by ultrasonic magnetic abrasive finishing[J].International journal of advanced manufacturing technology,2015,80(5-8):997-1005.
[14]JAIN V K,SAREN K K,RAGHURAM V,et al.Force analysis of magnetic abrasive nano-finishing of magnetic and non-magnetic materials[J].International journal of advanced manufacturing technology,2016,896:1-11.
[15]王瑜.永磁装置中磁场力的计算[J].磁性材料及器件,2007(5):49-52.WANG Yu.Calculation of magnetic force of permanent magnet devices[J].Journal of magnetic materials and devices,2007(5):49-52.
[16]杨海涛,张清林,陈大陆.柴油机喷嘴喷孔表面微观形貌测量及应用[J].表面技术,2017,46(12):283-289.YANG Hai-tao,ZHANG Qing-lin,CHEN Da-lu.Surface microstructure measurement and application of diesel engine nozzle holes[J].Surface technology,2017,46(12):283-289.