聚晶金刚石刀具磨削工艺参数优化及磨削机理研究
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摘要
聚晶金刚石是一种高硬度、高耐磨性的新型刀具材料，被广泛应用于工业领域。但它的难磨削性使它的推广应用又受到很大的限制，主要体现在磨削效率低、磨削成本高。如何提高磨削效率同时降低磨削成本成为国内外研究的重点和难点。
首先，本文通过试验，系统的研究了聚晶金刚石磨削工艺参数对磨削力、磨除率及磨耗比的影响规律，进而借助数学方法建立了砂轮线速度、工作台调定压力和进给量对磨削力、磨除率和磨耗比的数学模型，并通过优化方法得到了实现较高磨削效率和较低磨削成本的最优值，指出诸个工艺参数影响磨削力的强弱，推得了在各种情况下选择各工艺参数的原则。
其次，通过分析磨削后聚晶金刚石已加工表面的电子扫描显微镜照片，理清了聚晶金刚石的磨削机理，指出力和热的综合作用是聚晶金刚石去除的原因，其中包括磨料机械去除、脆性破裂去除和金刚石氧化、石墨化去除及高温塑性去除。
最后，本文运用推得的磨削机理分析了磨削工艺参数对磨削力、磨除率和磨耗比的影响规律，同时，也用磨削中的一些现象揭示了本文磨削机理的正确性。
The polycrystalline diamond (PCD) is applied widely in industrial fields as a new cutting tool material of high hardness and good wear-resistance. But its superhardness and high wear-resistance make it difficult to be grinded with the high grinding cost and low grinding efficiency and this restricts its popularity, therefore, how to improve grinding efficiency and lower grinding costs is an important and difficult job.
Through experiments, the effects of grinding process parameters on the grinding forces, removal rate and G-ratio when grinding PCD are studied. Furthermore, the mathematic models of the effects of wheel speed, contact force and feed on grinding forces, removal rate and G-ratio are constructed by means of regressive analysis. Moreover, the good process parameters of higher grinding efficiency and lower grinding costs are obtained through the mathematic method and the selecting principles of grinding process parameters on several typical conditions are gained.
On the other hand, the PCD grinding mechanism is clarified by analysing the surface image of grinded PCD through SEM. It is indicated that the synthetic actions of forces and heat are the main removal mechanism on PCD grinding, including mechanical removal, brittle fracture, graphitization and plastic deformation.
Finally, the effects of process parameters on PCD grinding are analysed by the grinding mechanism obtained in this paper and the grinding mechanism is verified through some phenomena.
首先，本文通过试验，系统的研究了聚晶金刚石磨削工艺参数对磨削力、磨除率及磨耗比的影响规律，进而借助数学方法建立了砂轮线速度、工作台调定压力和进给量对磨削力、磨除率和磨耗比的数学模型，并通过优化方法得到了实现较高磨削效率和较低磨削成本的最优值，指出诸个工艺参数影响磨削力的强弱，推得了在各种情况下选择各工艺参数的原则。
其次，通过分析磨削后聚晶金刚石已加工表面的电子扫描显微镜照片，理清了聚晶金刚石的磨削机理，指出力和热的综合作用是聚晶金刚石去除的原因，其中包括磨料机械去除、脆性破裂去除和金刚石氧化、石墨化去除及高温塑性去除。
最后，本文运用推得的磨削机理分析了磨削工艺参数对磨削力、磨除率和磨耗比的影响规律，同时，也用磨削中的一些现象揭示了本文磨削机理的正确性。
The polycrystalline diamond (PCD) is applied widely in industrial fields as a new cutting tool material of high hardness and good wear-resistance. But its superhardness and high wear-resistance make it difficult to be grinded with the high grinding cost and low grinding efficiency and this restricts its popularity, therefore, how to improve grinding efficiency and lower grinding costs is an important and difficult job.
Through experiments, the effects of grinding process parameters on the grinding forces, removal rate and G-ratio when grinding PCD are studied. Furthermore, the mathematic models of the effects of wheel speed, contact force and feed on grinding forces, removal rate and G-ratio are constructed by means of regressive analysis. Moreover, the good process parameters of higher grinding efficiency and lower grinding costs are obtained through the mathematic method and the selecting principles of grinding process parameters on several typical conditions are gained.
On the other hand, the PCD grinding mechanism is clarified by analysing the surface image of grinded PCD through SEM. It is indicated that the synthetic actions of forces and heat are the main removal mechanism on PCD grinding, including mechanical removal, brittle fracture, graphitization and plastic deformation.
Finally, the effects of process parameters on PCD grinding are analysed by the grinding mechanism obtained in this paper and the grinding mechanism is verified through some phenomena.
引文
1．肖诗刚．现代刀具材料．重庆大学出版社．1992．
2. G. Spur. Wire EDM of PCD. Industrial Diamond Review. 1988. (6):264～266.
3．丁涛．聚晶金刚石加工技术．机械设计与制造工程．2002(1)：3～4
4．张绍和等．化学镀-电镀金属化金刚石在钻头上的应用研究．金刚石与磨料磨具工具．1997(2)：16～18．
5. I.M. Kenter. Effect of process parameters when grinding PCD-1. Industrial Diamond Review.1992(1):29～33.
6. I.M. Kenter. Effect of process parameters when grinding PCD-2. Industrial Diamond Review.1992(2):75～80.
7. I.M. Kenter. Effect of process parameters when grinding PCD-3. Industrial Diamond Review.1992(6):313～318.
8. K.J. Dunn, M. Lee. The fracture and fatigue of sintered diamond compact. Journal of Material Science. 1979(14):882～890.
9. X. Ai, J. Zhang. Study on the grinding of polycrystalline diamond with slotted diamond wheels. Technical Paper-society of Manufacuring Engineers, MR1995.
10．王秦生．金刚石烧结制品．中国标准出版社．2000．
11．谢有赞．金刚石理论与合成技术．湖南科学技术出版社．1993．
12．张弘弢等．超硬材料聚晶金刚石(PCD)和聚晶立方氮化硼(PCBN)复合片刀具的应用．大连理工大学．1992．
13．马大刚．聚晶金刚石刀具刃磨机理及其刃磨砂轮制造工艺研究．大连理工大学硕士学位论文．2000(4)．
14．刘晋春．特种加工．机械工业出版社．1992．
15．张启斌．聚晶金刚石(PCD)刀具的刃磨及其刃磨砂轮的研究．大连理工大学硕士学位论文．1997(4)．
16．周泽华．金属切削原理．高等教育出版社．1990．
17．台湾产FC-200D型PCD&PCBN工具磨床说明书．
18．方开泰等．正交与均匀试验设计．科学出版社，2001．
19．滕素珍．数理统计。大连理工大学出版社．1996．
20．白新桂．数据分析与试验优化设计．清华大学出版社．1986．
21．唐焕文．最优化方法．大连理工大学出版社．1994．
22．余俊等．最优化方法及其应用．华中工学院出版社．1983．
23．胡峪等．VC++高级编程技巧与实例．西安电子科技大学出版社．2001．
24．李嫚等．聚晶金刚石刀具磨削机理试验研究．工具技术．录用待发．
25. T.K. Harris. Comparison of the creep properties of single crystal and polycrystalline diamond cutting tool materials. Diamond and Related Materials. 2001(10):755～759.
26. C.A. brooks. Mechanics of creep in brittle materials. Elsevier 1991:345～354.
27．任敬心等．难加工材料的磨削．国防工业出版社．1999．
28．濮良贵．机械设计．高等教育出版社．1996．
29．温诗铸．摩擦学原理．清华大学出版社．1992．
2. G. Spur. Wire EDM of PCD. Industrial Diamond Review. 1988. (6):264～266.
3．丁涛．聚晶金刚石加工技术．机械设计与制造工程．2002(1)：3～4
4．张绍和等．化学镀-电镀金属化金刚石在钻头上的应用研究．金刚石与磨料磨具工具．1997(2)：16～18．
5. I.M. Kenter. Effect of process parameters when grinding PCD-1. Industrial Diamond Review.1992(1):29～33.
6. I.M. Kenter. Effect of process parameters when grinding PCD-2. Industrial Diamond Review.1992(2):75～80.
7. I.M. Kenter. Effect of process parameters when grinding PCD-3. Industrial Diamond Review.1992(6):313～318.
8. K.J. Dunn, M. Lee. The fracture and fatigue of sintered diamond compact. Journal of Material Science. 1979(14):882～890.
9. X. Ai, J. Zhang. Study on the grinding of polycrystalline diamond with slotted diamond wheels. Technical Paper-society of Manufacuring Engineers, MR1995.
10．王秦生．金刚石烧结制品．中国标准出版社．2000．
11．谢有赞．金刚石理论与合成技术．湖南科学技术出版社．1993．
12．张弘弢等．超硬材料聚晶金刚石(PCD)和聚晶立方氮化硼(PCBN)复合片刀具的应用．大连理工大学．1992．
13．马大刚．聚晶金刚石刀具刃磨机理及其刃磨砂轮制造工艺研究．大连理工大学硕士学位论文．2000(4)．
14．刘晋春．特种加工．机械工业出版社．1992．
15．张启斌．聚晶金刚石(PCD)刀具的刃磨及其刃磨砂轮的研究．大连理工大学硕士学位论文．1997(4)．
16．周泽华．金属切削原理．高等教育出版社．1990．
17．台湾产FC-200D型PCD&PCBN工具磨床说明书．
18．方开泰等．正交与均匀试验设计．科学出版社，2001．
19．滕素珍．数理统计。大连理工大学出版社．1996．
20．白新桂．数据分析与试验优化设计．清华大学出版社．1986．
21．唐焕文．最优化方法．大连理工大学出版社．1994．
22．余俊等．最优化方法及其应用．华中工学院出版社．1983．
23．胡峪等．VC++高级编程技巧与实例．西安电子科技大学出版社．2001．
24．李嫚等．聚晶金刚石刀具磨削机理试验研究．工具技术．录用待发．
25. T.K. Harris. Comparison of the creep properties of single crystal and polycrystalline diamond cutting tool materials. Diamond and Related Materials. 2001(10):755～759.
26. C.A. brooks. Mechanics of creep in brittle materials. Elsevier 1991:345～354.
27．任敬心等．难加工材料的磨削．国防工业出版社．1999．
28．濮良贵．机械设计．高等教育出版社．1996．
29．温诗铸．摩擦学原理．清华大学出版社．1992．