锯切过程中工具与花岗石界面热特性研究
摘要
在锯切花岗石过程中，金刚石颗粒的非正常失效率高，造成金刚石圆锯片使用寿命下降，加工成本增加，生产效率降低。为了进一步提高生产效率，产品质量和降低生产成本，需要对锯切加工机理进行深入的研究，其中，研究金刚石颗粒在锯切过程中所承受的热负荷是一个很关键的研究内容。
与普通磨削加工相比，花岗石锯切加工的切深大，接触弧区长，并且弧区内有多个节块同时参与切削，热源模型复杂得多。
本文在已有的磨削温度研究成果的基础上，结合锯切加工的特殊性，推导出了三角形分布热源连续锯切二维稳态温度场模型，连续锯切非稳态温度场模型，断续锯切温度场模型，以及在无冷却液锯切情况下锯切热量的分配比例占理论模型。本文还采用热电偶夹丝测温法实际测量了锯切弧区工件表面温度分布曲线，并通过实测温度曲线与理论温度曲线拟合的方法求出在无冷却液锯切花岗石的热量分配比例占。
研究结果表明，本文推导的温度理论模型能较好的反映实际加工过程中工具与花岗石界面间的温度特征。与磨削金属工件相反的是，锯切产生的热量只有一小部分(约8％)传入到花岗石，其它大部分热量传入到节块内，这与金刚石导热性能优异，而花岗石的导热性能差有直接的关系。
本文的研究有助于深入了解花岗石锯切过程中的热现象，为进一步研究金刚石颗粒在花岗石锯切过程中所承受的热负荷提供基础数据。
与普通磨削加工相比，花岗石锯切加工的切深大，接触弧区长，并且弧区内有多个节块同时参与切削，热源模型复杂得多。
本文在已有的磨削温度研究成果的基础上，结合锯切加工的特殊性，推导出了三角形分布热源连续锯切二维稳态温度场模型，连续锯切非稳态温度场模型，断续锯切温度场模型，以及在无冷却液锯切情况下锯切热量的分配比例占理论模型。本文还采用热电偶夹丝测温法实际测量了锯切弧区工件表面温度分布曲线，并通过实测温度曲线与理论温度曲线拟合的方法求出在无冷却液锯切花岗石的热量分配比例占。
研究结果表明，本文推导的温度理论模型能较好的反映实际加工过程中工具与花岗石界面间的温度特征。与磨削金属工件相反的是，锯切产生的热量只有一小部分(约8％)传入到花岗石，其它大部分热量传入到节块内，这与金刚石导热性能优异，而花岗石的导热性能差有直接的关系。
本文的研究有助于深入了解花岗石锯切过程中的热现象，为进一步研究金刚石颗粒在花岗石锯切过程中所承受的热负荷提供基础数据。
引文
1.ER.Davis, "The Future of diamond abrasives in stone processing," Proc. Of International Conference on Diamond, CBN & Their Applications (Intertech'2000), Vancour, Canada, July, 2000.
2．李志宏等．我国人造金刚石工业现状及发展．金刚石与磨料磨具工程，2002，1：pp49～53
3．李远，锯切花岗石过程中的力和能量特征：[硕士学位论文]．华侨大学，1999，
4．黄辉．金刚石圆锯片锯切花岗石过程中锯切弧区载荷和温度特征研究．华侨大学硕士学位论文，1998．6．
5．于怡青等．金刚石节块与花岗石界面锯切温度的测量与分析．工具技术，2001年第35卷N06，pp8～11．
6．徐西鹏，Malkin. S. 金刚石砂轮／花岗石摩擦界面能量传输的实验研究．磨擦学报，2000．6
7．兰雄侯，王继先，高航，磨削温度理论研究的现状与进展．金刚石与磨料磨具工程，2001，3：pp：5～6．
8．徐鸿钧 磨削温度的测量技术 磨料磨具与磨削，1986，6(36)．
9．徐西鹏，徐鸿钧 磨削弧区温度在线监测技术研究，制造技术与机床，1995，3．
10．侯镇冰，何绍杰，李恕先，固体热传导，上海科技出版社，1984．
11．武志斌，高效磨削的瓶颈与对策：[博士学位论文)。南京航空航天大学，2001．5，
12．徐西鹏，难加工材料高效深切磨削的基础研究：[博士学位论文]．南京航空航天大学，1992．
13.T. Jin, GQ.Cai. "Analytical thermal models of oblique moving heat source for deep grinding and cutting," Journal of Manufacturing Science and Engineering, May 2001, Vol.123, pp185～190.
14.W.B.Rowe, T. Jin. "Temperatures in High Efficiency Deep Grinding(HEDG)," Annals of the CIRP, Vol.50/1/2001, pp205～208.
15．傅玉灿，进一步开发高效磨削潜力的基础研究：[博士学位论文]．南京航空航天大学，1999，6
16.A.S.Lavine,S.Malkin,T.C.Jen. "Thermal Aspects of Grinding with CBN Wheels," Annals of the CIRP ,Vol.38/1/1989,pp557～560.
17.Jaeger, J. "Moving Sources of Heat and Temperature at Sliding Contacts," Proc. of the Royal Society of New South Wales, Vol.76, 1942, pp.203-224.
18.W. Brian Rowe. "Thermal analysis of high efficency deep grinding, "International Journal of Machine Tools & Manufacture, Vol.41 (2001): pp 1～19.
19.S.Kohli,C.Guo,S.Malkin. "Energy Partition to the Workpiece for Grinding with Aluminum Oxide and CBN Abrasive Wheels," Transactions of the ASME, Vol.117,May 1995:pp160～168.
20.C.Guo, S.Malkin. "Analysis of Energy Partition in Grinding," Journal of Engineering for Industry, Februaly 1995, Vol. 117, pp55～62.
21.B.Zhu, C.Guo, J.E.Sunderland, S.Malkin. "Energy Partition to the Workpiece for
Grinding of Ceramics," Annals of the CIRP, Vol.44/1/1995, pp267-271．
22． C.Guo, S.Malkin. "Heat Transfer in Grinding," Journal of Materials Processing & Manufacturing Science, Vol. 1, No. 1, pp. 16-27．
23． S.Malkin, R.B.Anderson. "Thermal Aspects of Grinding:Part 1-Energy Partition," Journal of Engineering for Industry, November 1974, pp 1177-1183．
24． Adrienne S.Lavine. " Analysis of Thermal Aspects of Grinding:Heat Transfer to Workpiece,Wheel,and Fluid," Proceedings of NSF Design and Manufacturing Systems Conference, January 8-12,1990, pp497-502．
25． Adrienne S.Lavine,S.Malkin. " The Role of Cooling in Creep Feed Grinding," Third Int 't Grinding Conf., SME Paper No, MR88-618．
26． T.Kato, H.Fujii. " Energy Partition in Conventional Surface Grinding," Journal of Manufacturing Science and Engeneering, August 1999, Vol.121, pp393-398．
27． W.B.Rowe, S.C.E.Black, B.Mills, H.S.Qi. "Analysis of grinding temperatures by energy partitioning," Proc Instn Mech Engrs, Vol 210, pp579-588．
28． Adrienne S.Lavine. "A simple Model for Convective Cooling During the Grinding Process," Journal of Engineering for Industry, February 1988, Vol.110, pp1-6．
29． Trevor Howes. "Assessment of the Cooling and Lubricative Properties of Grinding Fluids, " Annals of the CIRP, Vol.39/1/1990, pp313-316．
30． M.C.Shaw, "A simplified Approach to Workpiece Temperatures in Fine Grinding," Ann.CIRP,1990,39(1) , pp345-347．
31． N.K.Kim, C.Guo, S.Malkon. "Heat Flux Distribution and Energy Partition in Creep-Feed Grinding," Annals of the CIRP, Vol.97, pp227-232．
32． W.B.Rowe, M.N.Morgan, S.C.E.Black. "Validation of Thermal Properties in Grinding," Annals of the CIRP, Vol.47/1/1998, pp339-345．
33． Takashi Ueda,Akira Hosokawa, Akira Yamamoto. "Studies on Temperature of Abrasive Grains in Grinding-Application of Infrared Radiation Pyrometer, " Journal of Engineering for Industry, May 1985, Vol.107,pp127133．
34． Xipeng Xu, S.Malkin. "Comparison of Methods to Measure Grinding Temperatures," Journal of Manufacturing Science and Engineering, May 2001, Vol.123, pp191-195．
35． S.C.E.Black, W.B.Rowe, B.Mills, H.S.Qi. "Experiment Energy Partitioning in Grinding," ImechE Mission of Tribology 3, 6th Dec. 1994．
36． J.E.Morgan, J.A.Scott. "Temperature Measurement When Diamond Grinding Ceramics," IDR 2/92, pp65-69．
37． T.Kato, H.Fujii. "Temperature Measurement of Workpiece in Surface Grinding by PVD Film Method," Journal of Manufacturing Science and Engineering, November 1997, Vol.119, pp689-694．
38． 任敬心,康仁科,史兴宽,难加工材料的磨削,国防工业出版社, 1999．
39． 李伯民,赵波,实用磨削技术,机械工业出版社, 1996．
40． 张幼桢,金属切削理论,航空工业出版社, 1988．
2．李志宏等．我国人造金刚石工业现状及发展．金刚石与磨料磨具工程，2002，1：pp49～53
3．李远，锯切花岗石过程中的力和能量特征：[硕士学位论文]．华侨大学，1999，
4．黄辉．金刚石圆锯片锯切花岗石过程中锯切弧区载荷和温度特征研究．华侨大学硕士学位论文，1998．6．
5．于怡青等．金刚石节块与花岗石界面锯切温度的测量与分析．工具技术，2001年第35卷N06，pp8～11．
6．徐西鹏，Malkin. S. 金刚石砂轮／花岗石摩擦界面能量传输的实验研究．磨擦学报，2000．6
7．兰雄侯，王继先，高航，磨削温度理论研究的现状与进展．金刚石与磨料磨具工程，2001，3：pp：5～6．
8．徐鸿钧 磨削温度的测量技术 磨料磨具与磨削，1986，6(36)．
9．徐西鹏，徐鸿钧 磨削弧区温度在线监测技术研究，制造技术与机床，1995，3．
10．侯镇冰，何绍杰，李恕先，固体热传导，上海科技出版社，1984．
11．武志斌，高效磨削的瓶颈与对策：[博士学位论文)。南京航空航天大学，2001．5，
12．徐西鹏，难加工材料高效深切磨削的基础研究：[博士学位论文]．南京航空航天大学，1992．
13.T. Jin, GQ.Cai. "Analytical thermal models of oblique moving heat source for deep grinding and cutting," Journal of Manufacturing Science and Engineering, May 2001, Vol.123, pp185～190.
14.W.B.Rowe, T. Jin. "Temperatures in High Efficiency Deep Grinding(HEDG)," Annals of the CIRP, Vol.50/1/2001, pp205～208.
15．傅玉灿，进一步开发高效磨削潜力的基础研究：[博士学位论文]．南京航空航天大学，1999，6
16.A.S.Lavine,S.Malkin,T.C.Jen. "Thermal Aspects of Grinding with CBN Wheels," Annals of the CIRP ,Vol.38/1/1989,pp557～560.
17.Jaeger, J. "Moving Sources of Heat and Temperature at Sliding Contacts," Proc. of the Royal Society of New South Wales, Vol.76, 1942, pp.203-224.
18.W. Brian Rowe. "Thermal analysis of high efficency deep grinding, "International Journal of Machine Tools & Manufacture, Vol.41 (2001): pp 1～19.
19.S.Kohli,C.Guo,S.Malkin. "Energy Partition to the Workpiece for Grinding with Aluminum Oxide and CBN Abrasive Wheels," Transactions of the ASME, Vol.117,May 1995:pp160～168.
20.C.Guo, S.Malkin. "Analysis of Energy Partition in Grinding," Journal of Engineering for Industry, Februaly 1995, Vol. 117, pp55～62.
21.B.Zhu, C.Guo, J.E.Sunderland, S.Malkin. "Energy Partition to the Workpiece for
Grinding of Ceramics," Annals of the CIRP, Vol.44/1/1995, pp267-271．
22． C.Guo, S.Malkin. "Heat Transfer in Grinding," Journal of Materials Processing & Manufacturing Science, Vol. 1, No. 1, pp. 16-27．
23． S.Malkin, R.B.Anderson. "Thermal Aspects of Grinding:Part 1-Energy Partition," Journal of Engineering for Industry, November 1974, pp 1177-1183．
24． Adrienne S.Lavine. " Analysis of Thermal Aspects of Grinding:Heat Transfer to Workpiece,Wheel,and Fluid," Proceedings of NSF Design and Manufacturing Systems Conference, January 8-12,1990, pp497-502．
25． Adrienne S.Lavine,S.Malkin. " The Role of Cooling in Creep Feed Grinding," Third Int 't Grinding Conf., SME Paper No, MR88-618．
26． T.Kato, H.Fujii. " Energy Partition in Conventional Surface Grinding," Journal of Manufacturing Science and Engeneering, August 1999, Vol.121, pp393-398．
27． W.B.Rowe, S.C.E.Black, B.Mills, H.S.Qi. "Analysis of grinding temperatures by energy partitioning," Proc Instn Mech Engrs, Vol 210, pp579-588．
28． Adrienne S.Lavine. "A simple Model for Convective Cooling During the Grinding Process," Journal of Engineering for Industry, February 1988, Vol.110, pp1-6．
29． Trevor Howes. "Assessment of the Cooling and Lubricative Properties of Grinding Fluids, " Annals of the CIRP, Vol.39/1/1990, pp313-316．
30． M.C.Shaw, "A simplified Approach to Workpiece Temperatures in Fine Grinding," Ann.CIRP,1990,39(1) , pp345-347．
31． N.K.Kim, C.Guo, S.Malkon. "Heat Flux Distribution and Energy Partition in Creep-Feed Grinding," Annals of the CIRP, Vol.97, pp227-232．
32． W.B.Rowe, M.N.Morgan, S.C.E.Black. "Validation of Thermal Properties in Grinding," Annals of the CIRP, Vol.47/1/1998, pp339-345．
33． Takashi Ueda,Akira Hosokawa, Akira Yamamoto. "Studies on Temperature of Abrasive Grains in Grinding-Application of Infrared Radiation Pyrometer, " Journal of Engineering for Industry, May 1985, Vol.107,pp127133．
34． Xipeng Xu, S.Malkin. "Comparison of Methods to Measure Grinding Temperatures," Journal of Manufacturing Science and Engineering, May 2001, Vol.123, pp191-195．
35． S.C.E.Black, W.B.Rowe, B.Mills, H.S.Qi. "Experiment Energy Partitioning in Grinding," ImechE Mission of Tribology 3, 6th Dec. 1994．
36． J.E.Morgan, J.A.Scott. "Temperature Measurement When Diamond Grinding Ceramics," IDR 2/92, pp65-69．
37． T.Kato, H.Fujii. "Temperature Measurement of Workpiece in Surface Grinding by PVD Film Method," Journal of Manufacturing Science and Engineering, November 1997, Vol.119, pp689-694．
38． 任敬心,康仁科,史兴宽,难加工材料的磨削,国防工业出版社, 1999．
39． 李伯民,赵波,实用磨削技术,机械工业出版社, 1996．
40． 张幼桢,金属切削理论,航空工业出版社, 1988．