液—粒两相强制环流内孔表面光整加工装置设计与实验研究
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摘要
本课题来源于国家自然科学基金项目“面向孔表面光整加工的液粒两相强制环流理论与技术基础的研究(50675149)”,课题主要研究液粒两相强制环流光整加工技术。其加工原理为：具有一定压力的液体经过环流发生装置,在工件内形成强制环流,带动磨粒进行环流运动,磨粒在强大的离心力的作用下,对工件内壁进行滚压、刻划等作用,再加上液体自身具有的巨大能量对工件内表面的冲击作用,从而实现内孔表面的光整加工
本论文的主要内容为：阐述了传统的孔表面光整加工工艺；介绍了两相流与螺旋流的相关知识以及液粒两相强制环流的光整加工机理；利用计算机仿真软件FLUENT对提出的几种装置模型进行仿真模拟,考虑仿真模拟结果、装置制造的难易以及经济成本等方面,确定实验装置模型为液粒两相强制环流发生器；根据装置模型进行装置的相关设计；最后进行基础性实验,验证该工艺的可行性以及液体流量大小、喷嘴数量、喷嘴位置等因素对加工质量和加工效率的影响。
该工艺的成功应用,将创造出一个适用范围广泛的光整加工新办法来解决内孔表面的光整难题,并能整体改善零件加工表面的物理力学性能,为此工艺的普及应用提供了有利的理论基础及实验依据；而且还能使传统光整加工技术和非传统光整加工技术得到进一步的完善,提高我国光整加工技术的水平,推动相关行业的发展,产生重大的社会效益和经济效益。
The research is supported by the nation science fund project (50675149) which research on "Theory and Technological Basis of Liquid-Particle Two-Phase Compulsive Circumfluence Oriented Hole Surface Finishing", to research liquid-particle two-phase compulsive circumfluence finishing technique. Through the circulation occurs device, compulsive circulation is formed by the liquid, which has a certain pressure. It stimulates particles to make circulation movement. Particles have the function of rolling, scoring, etc., for the hole surface by means of strong centrifugal force, and the liquid has the tremendous energy to impact the hole surface, to achieve the hole surface finishing.
The primary content of thesis:expatiating traditional technology of hole surface finishing; introducing correlation knowledge of two-phase flow and spiral flow and the finishing principle of liquid-particle two phase compulsive circulation finishing, carrying through simulation of some equipment former be mentioned by FLUENT software, deciding to adopt set of liquid-particle two-phase compulsive circulation flows finishing considering simulation result. difficult or easy in manufacturing and cost etc; carrying through correlation device design by selected equipment; finally, the device be processed to put up some basic experiment, so that the feasibility of this technology and infection of quality and efficiency in magnitude of liquid flux、nozzle amount、nozzle position and so on can be validated.
The success application of this technology will have a broad scope of application, and create a new approach to solve the hole surface finishing problems. It can improve overall physical and mechanical properties of part surface, providing a favorable theoretical basis and data for the wider application of this technology. Simultaneously, the traditional finishing technologies and non-traditional finishing techniques can be further improved, enhancing finishing skill levels, promoting the development of related industries, having significant social and economic benefits.
本论文的主要内容为：阐述了传统的孔表面光整加工工艺；介绍了两相流与螺旋流的相关知识以及液粒两相强制环流的光整加工机理；利用计算机仿真软件FLUENT对提出的几种装置模型进行仿真模拟,考虑仿真模拟结果、装置制造的难易以及经济成本等方面,确定实验装置模型为液粒两相强制环流发生器；根据装置模型进行装置的相关设计；最后进行基础性实验,验证该工艺的可行性以及液体流量大小、喷嘴数量、喷嘴位置等因素对加工质量和加工效率的影响。
该工艺的成功应用,将创造出一个适用范围广泛的光整加工新办法来解决内孔表面的光整难题,并能整体改善零件加工表面的物理力学性能,为此工艺的普及应用提供了有利的理论基础及实验依据；而且还能使传统光整加工技术和非传统光整加工技术得到进一步的完善,提高我国光整加工技术的水平,推动相关行业的发展,产生重大的社会效益和经济效益。
The research is supported by the nation science fund project (50675149) which research on "Theory and Technological Basis of Liquid-Particle Two-Phase Compulsive Circumfluence Oriented Hole Surface Finishing", to research liquid-particle two-phase compulsive circumfluence finishing technique. Through the circulation occurs device, compulsive circulation is formed by the liquid, which has a certain pressure. It stimulates particles to make circulation movement. Particles have the function of rolling, scoring, etc., for the hole surface by means of strong centrifugal force, and the liquid has the tremendous energy to impact the hole surface, to achieve the hole surface finishing.
The primary content of thesis:expatiating traditional technology of hole surface finishing; introducing correlation knowledge of two-phase flow and spiral flow and the finishing principle of liquid-particle two phase compulsive circulation finishing, carrying through simulation of some equipment former be mentioned by FLUENT software, deciding to adopt set of liquid-particle two-phase compulsive circulation flows finishing considering simulation result. difficult or easy in manufacturing and cost etc; carrying through correlation device design by selected equipment; finally, the device be processed to put up some basic experiment, so that the feasibility of this technology and infection of quality and efficiency in magnitude of liquid flux、nozzle amount、nozzle position and so on can be validated.
The success application of this technology will have a broad scope of application, and create a new approach to solve the hole surface finishing problems. It can improve overall physical and mechanical properties of part surface, providing a favorable theoretical basis and data for the wider application of this technology. Simultaneously, the traditional finishing technologies and non-traditional finishing techniques can be further improved, enhancing finishing skill levels, promoting the development of related industries, having significant social and economic benefits.
引文
[1]周锦进,方建成,徐文冀.光整加工技术的研究和发展[J].制造技术与机床,2004(3)：7-10.
[2]杨世春,汪鸣铮,张银喜.表面质量与光整技术[M].北京：机械工业出版社,2000：35-49.
[3]汪鸣铮.滚磨光整加工工艺[J].新技术新工艺,1995(5)：18-19.
[4]王时英,吕 明,轧刚.磨料流加工的力学原理及应用[J].太原理工大学学报,1998,29(3)：272-275.
[5]王时英.磨料流加工机理的研究[D].太原：太原工业大学,1990.
[6]方筱萍.内孔滚压加工方法的研究[J].农业机械学报,1997,28(3)：123-127.
[7]王维新.内孔滚压加工及其影响因素的分析[J].西北轻工业学学院学报,2002.10：67-72.
[8]Jeong-Du Kim, Youn-Hee Kang, Young-Han Bae. Development of a magnetic abrasive jet machining system for precision internal polishing of circular tubes[J]. Journal of Materials Processing Technology,1997:384-393.
[9]何根旺.液粒两相螺旋流光整加工技术的理论研究及螺旋流仿真分析[D].太原：太原理工大学,2006.
[10]侯志燕.高能液粒两相螺旋流光整加工技术的基本理论研究[D].太原：太原理工大学,2005.
[11]郭燕莹,张银喜,杨世春.内圆表面磁性研磨加工的研究[J].中国机械工程,1997,8(6)：23-25.
[12]尚宝平,江世碌.小孔径内圆表面磁性研磨加工实验研究[J].金刚石与磨料磨具工程,2006,151(1)：57-59.
[13]方建成,张海鸥.不锈钢管内孔旋转磁场磁粒光整加工[J].机械科学与技术,2001,20(1)：92-93.
[14]陈燕.应用磁研磨法对细长管内表面的抛光处理[J].磨具制造技术,2004(10)：49-50.
[15]N. Umehara, T. Kobayashi, K. kato. Internal polishing of tube with magnetic fluid
grinding Part2, fundamental polishing properties with rotating balls and with oscilling ball, Journal of Magnetic Materials,1995:188-191.
[16]杨胜强.面向内孔表面两相螺旋流光整加工技术的理论分析与实验研究[D].太原：太原理工大学,2008.
[17]王献孚,熊鳌魁.高等流体力学[M].武汉：华中科技大学出版社,2003：90.
[18]王晓飞.管内螺旋流的实验与分析[D].武汉：武汉理工大学,2004.
[19]山东工学院,东北电力学院.工程流体力学[M].北京：水利电力出版社,1984：170-172.
[20]吴望一.流体力学[M].北京：北京大学出版社,1983.
[21]陈卓如,金朝铭,王洪杰,等.工程流体力学(第二版)[M].高等教育出版社,147.
[22]熊鳌魁.强稳定螺旋流现象研究及非线性涡粘性模式的应用[D].北京大学(博士学位论文),1998：4-6.
[23]张香红.气-固两相螺旋流光整加工技术的理论分析与数值模拟研究[D].太原：太原理工大学,2007.
[24]熊鳌魁,魏庆鼎.一种强螺旋流现象的实验研究[J].流体力学实验与测量,1999,13(4)： 8-13.
[25]熊鳌魁,魏庆鼎.一类变截面管内轴对称螺旋流的衰减规律分析[J].应用数学和力学,2001,22(8)：879-883.
[26]孙西欢.水平轴圆管螺旋流水力特性及固粒悬浮机理的实验研究[D].西安理工大学(博士学位论文),2000：5-10.
[27]S.Q.Yang. Technology Research on Whirling Air-Stream Finishing of Precision Hole Surface, Proceedings of the First International Conference on Mechanical Engineering (China Machine Press 2000):124.
[28]J.Pruvost, Legrand, P.Legentilhomme, L.Doubliez. Particleimageveloci-metry investigation of the flow-field of a 3D turbulent annular swirling decaying flow induced by means of a tangential inlet. Experiment in Fluids 29(2000)291-301, Springer-Verlag 2000.
[29]HORII K, MURATA T, TAKARADA M and MARUI T. A study of spiral flow (Part1):
Phenomenon in a cylindrical pipe. Trans.Japan Soc.Aero.Space Sci.1985,28(81).
[30]J.Pruvost, Legrand, P.Legentilhomme, L.Doubliez. Particleimageveloci-metry investigation of the flow-field of a 3D turbulent annular swirling decaying flow induced by means of a tangential inlet. Experiment in Fluids 29(2000)291-301, Springer-Verlag 2000.
[31]HORII K, MATSUMAE Y, TAKEIM. An erosion resistant bend to theory and development-Industrial Appl. Fluid Mech.ASME FED2 1988b, Vol.70.
[32]HORII K, SATSUMAE Y, CHENGXM, TAKEIM and HASHIMOTO B. A study of spiral flow(part3):Opening and orientation control of fiber by spiral flow trans. Japan Soc.Aero.Space Sci.1990a32(98).
[33]HORII K, MATSUMAE Y, CHENG XM, TAKEIM and HASHIMOTO B. A study of spiral flow (Part4):The effect of radial reynolds number of spiral flow on plasma deposition of pipe. Trans.Japan Soc.Aero.Space Sci.1990b,32(98).
[34]HORII K, MATSUMAE Y, CHENGXM and HASHIMOTO B.A study of spiral flow (Part5):Analysis of frictional force acting on short fiber.Trans.Japan Soc.Aero. Space Sci.1990c,32(98).
[35]HORII K, SAWAZAKI H, MATSUMAE Y, CHENG XM, TAKEIM, YASUKAWA E and HASHIMOTO B. New continuous systemfor dispersion and encapsulation of submicron powders using spiral flow.-Industrial Appl.Fluid Mech.ASME FED2 1990d, Vol.100.
[36]HORII K, MATSUMAE Y, OHSUMI K, CHENG XM, KAGE S and HASHIMOTO B. Novel optical fiber installation by use of spiral airflow.-Industrial Appl.Fluid Mech.ASME FED21991a Vol.132.
[37]HORII K, MATSUMAE Y, OHSUMI K, CHENG XM, TAKEI M, YASUKAWA E and HASHIMOTO B. Focusing phenomenon and stability of spiral flow jet.Trans.Japan Soc.Aero.Space Sci.1991b,33(102):1.
[38]李晓钟,陈文梅,褚良银.水力旋流器能耗定义及其组成分析[J].过滤与分离,2000,10(2)： 1-3.
[39]褚良银,吴持恭,等.水力旋流器湍流结构控制与能耗降减[J].化工学报,1998,
49(6)：760-763.
[40]褚良银.水力旋流器能耗机制与节能原理研究[R].博士后研究工作报告.四川联合大学,1997.3.
[41]徐继润,罗茜.水力旋流器流场理论[M].北京：科学出版社,1998.
[42]褚良银,陈文梅,等.水力旋流器[M].北京：化学工业出版社,1998.
[43]阎庆绂.离心泵入口旋流的试验研究[J].农业机械学报,1992,23(1)：45-51.
[44]马素霞.泵入口旋流的试验研究[D].山西：太原工业大学,1997.
[45]Atkinson E. Vortex-tube sediment extractor. Part Ⅰ:Trapping efficiency. J Hydr Engyg, ASCE,1994,120(10):1110-1125.
[46]陈仰吾,郭天恩,高恩恩.涡管流管道排除水库泥沙的机理研究[J].水利水电技术,1993(2)：53-56.
[47]唐毅,吴持恭,周著.排沙漏斗三维涡流水流结构[J].水利学报,1999(4)：55-59.
[48]马向阳.旋涡气流光整加工工艺研究[D].太原：太原理工大学,2003：15-18.
[49]韩占忠,王敬,兰小平.FLUENT流体工程防真计算实例与应用[M].北京理工大学出版社,19-22.
[50]赵军英,杨胜强,李文辉,等.光整加工中两种旋涡流流场的计算机仿真与比较[J].新技术新工艺,2008(4)：27-29.
[51]方丁酋.两相流动力学[M].湖南：国防科技大学出版社,1988：43-68.
[2]杨世春,汪鸣铮,张银喜.表面质量与光整技术[M].北京：机械工业出版社,2000：35-49.
[3]汪鸣铮.滚磨光整加工工艺[J].新技术新工艺,1995(5)：18-19.
[4]王时英,吕 明,轧刚.磨料流加工的力学原理及应用[J].太原理工大学学报,1998,29(3)：272-275.
[5]王时英.磨料流加工机理的研究[D].太原：太原工业大学,1990.
[6]方筱萍.内孔滚压加工方法的研究[J].农业机械学报,1997,28(3)：123-127.
[7]王维新.内孔滚压加工及其影响因素的分析[J].西北轻工业学学院学报,2002.10：67-72.
[8]Jeong-Du Kim, Youn-Hee Kang, Young-Han Bae. Development of a magnetic abrasive jet machining system for precision internal polishing of circular tubes[J]. Journal of Materials Processing Technology,1997:384-393.
[9]何根旺.液粒两相螺旋流光整加工技术的理论研究及螺旋流仿真分析[D].太原：太原理工大学,2006.
[10]侯志燕.高能液粒两相螺旋流光整加工技术的基本理论研究[D].太原：太原理工大学,2005.
[11]郭燕莹,张银喜,杨世春.内圆表面磁性研磨加工的研究[J].中国机械工程,1997,8(6)：23-25.
[12]尚宝平,江世碌.小孔径内圆表面磁性研磨加工实验研究[J].金刚石与磨料磨具工程,2006,151(1)：57-59.
[13]方建成,张海鸥.不锈钢管内孔旋转磁场磁粒光整加工[J].机械科学与技术,2001,20(1)：92-93.
[14]陈燕.应用磁研磨法对细长管内表面的抛光处理[J].磨具制造技术,2004(10)：49-50.
[15]N. Umehara, T. Kobayashi, K. kato. Internal polishing of tube with magnetic fluid
grinding Part2, fundamental polishing properties with rotating balls and with oscilling ball, Journal of Magnetic Materials,1995:188-191.
[16]杨胜强.面向内孔表面两相螺旋流光整加工技术的理论分析与实验研究[D].太原：太原理工大学,2008.
[17]王献孚,熊鳌魁.高等流体力学[M].武汉：华中科技大学出版社,2003：90.
[18]王晓飞.管内螺旋流的实验与分析[D].武汉：武汉理工大学,2004.
[19]山东工学院,东北电力学院.工程流体力学[M].北京：水利电力出版社,1984：170-172.
[20]吴望一.流体力学[M].北京：北京大学出版社,1983.
[21]陈卓如,金朝铭,王洪杰,等.工程流体力学(第二版)[M].高等教育出版社,147.
[22]熊鳌魁.强稳定螺旋流现象研究及非线性涡粘性模式的应用[D].北京大学(博士学位论文),1998：4-6.
[23]张香红.气-固两相螺旋流光整加工技术的理论分析与数值模拟研究[D].太原：太原理工大学,2007.
[24]熊鳌魁,魏庆鼎.一种强螺旋流现象的实验研究[J].流体力学实验与测量,1999,13(4)： 8-13.
[25]熊鳌魁,魏庆鼎.一类变截面管内轴对称螺旋流的衰减规律分析[J].应用数学和力学,2001,22(8)：879-883.
[26]孙西欢.水平轴圆管螺旋流水力特性及固粒悬浮机理的实验研究[D].西安理工大学(博士学位论文),2000：5-10.
[27]S.Q.Yang. Technology Research on Whirling Air-Stream Finishing of Precision Hole Surface, Proceedings of the First International Conference on Mechanical Engineering (China Machine Press 2000):124.
[28]J.Pruvost, Legrand, P.Legentilhomme, L.Doubliez. Particleimageveloci-metry investigation of the flow-field of a 3D turbulent annular swirling decaying flow induced by means of a tangential inlet. Experiment in Fluids 29(2000)291-301, Springer-Verlag 2000.
[29]HORII K, MURATA T, TAKARADA M and MARUI T. A study of spiral flow (Part1):
Phenomenon in a cylindrical pipe. Trans.Japan Soc.Aero.Space Sci.1985,28(81).
[30]J.Pruvost, Legrand, P.Legentilhomme, L.Doubliez. Particleimageveloci-metry investigation of the flow-field of a 3D turbulent annular swirling decaying flow induced by means of a tangential inlet. Experiment in Fluids 29(2000)291-301, Springer-Verlag 2000.
[31]HORII K, MATSUMAE Y, TAKEIM. An erosion resistant bend to theory and development-Industrial Appl. Fluid Mech.ASME FED2 1988b, Vol.70.
[32]HORII K, SATSUMAE Y, CHENGXM, TAKEIM and HASHIMOTO B. A study of spiral flow(part3):Opening and orientation control of fiber by spiral flow trans. Japan Soc.Aero.Space Sci.1990a32(98).
[33]HORII K, MATSUMAE Y, CHENG XM, TAKEIM and HASHIMOTO B. A study of spiral flow (Part4):The effect of radial reynolds number of spiral flow on plasma deposition of pipe. Trans.Japan Soc.Aero.Space Sci.1990b,32(98).
[34]HORII K, MATSUMAE Y, CHENGXM and HASHIMOTO B.A study of spiral flow (Part5):Analysis of frictional force acting on short fiber.Trans.Japan Soc.Aero. Space Sci.1990c,32(98).
[35]HORII K, SAWAZAKI H, MATSUMAE Y, CHENG XM, TAKEIM, YASUKAWA E and HASHIMOTO B. New continuous systemfor dispersion and encapsulation of submicron powders using spiral flow.-Industrial Appl.Fluid Mech.ASME FED2 1990d, Vol.100.
[36]HORII K, MATSUMAE Y, OHSUMI K, CHENG XM, KAGE S and HASHIMOTO B. Novel optical fiber installation by use of spiral airflow.-Industrial Appl.Fluid Mech.ASME FED21991a Vol.132.
[37]HORII K, MATSUMAE Y, OHSUMI K, CHENG XM, TAKEI M, YASUKAWA E and HASHIMOTO B. Focusing phenomenon and stability of spiral flow jet.Trans.Japan Soc.Aero.Space Sci.1991b,33(102):1.
[38]李晓钟,陈文梅,褚良银.水力旋流器能耗定义及其组成分析[J].过滤与分离,2000,10(2)： 1-3.
[39]褚良银,吴持恭,等.水力旋流器湍流结构控制与能耗降减[J].化工学报,1998,
49(6)：760-763.
[40]褚良银.水力旋流器能耗机制与节能原理研究[R].博士后研究工作报告.四川联合大学,1997.3.
[41]徐继润,罗茜.水力旋流器流场理论[M].北京：科学出版社,1998.
[42]褚良银,陈文梅,等.水力旋流器[M].北京：化学工业出版社,1998.
[43]阎庆绂.离心泵入口旋流的试验研究[J].农业机械学报,1992,23(1)：45-51.
[44]马素霞.泵入口旋流的试验研究[D].山西：太原工业大学,1997.
[45]Atkinson E. Vortex-tube sediment extractor. Part Ⅰ:Trapping efficiency. J Hydr Engyg, ASCE,1994,120(10):1110-1125.
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