化学辅助软磨粒流抛光技术研究
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摘要
模具是零件成型过程的重要工艺装备,模具应用领域不断扩大。随着市场竞争的白热化,人们对模具提出了越来越高的要求。模具正朝着大型、复杂、精密化方向发展。复杂的模具中往往存在大量的沟、槽、孔等结构化表面,受尺寸、形状限制而无法使用工具进行接触式加工,这一点成为模具制造业急需解决的技术难题。为了解决这一现实问题,本文提出了针对模具结构化表面的化学辅助软磨粒流抛光方法。
化学辅助软磨粒流抛光分为化学抛光、软磨粒流抛光两个阶段。化学抛光工艺简单,操作方便,不受零件形状尺寸的限制,同时化学抛光可除去零件表面的机械损伤层和应力层；化学抛光后的零件表面因为发生了化学反应降低了表面原子的键合能力,提高了软磨粒流抛光的效率。同时,软磨粒流抛光也是化学抛光的一种补充,协助除去表面未溶解的金属氧化物,同时清洗残留的化学液。为了使两个阶段能够起到很好的协调组合作用,需要研究这两个阶段的工艺过程、加工机理等,各章节都仅仅围绕以上需要解决的问题进行展开。本文的主要工作如下：
(1)应用数值模拟技术对软磨粒抛光中流体的湍流特性进行了研究。为了得到洋实的湍流信息,采用大涡数值模拟和雷诺平均模拟两种湍流数值模拟方法进行研究。从理论上,分析了大涡数值模拟和属于雷诺平均模拟的可实现κ-ε模型的特点,建立“M”形的弯形流道为数值模拟的几何模型,在初始条件、边界条件、计算方法都相同的情况下,分别采用大涡模拟和可实现κ-ε模型两种不同的湍流模拟方法分别对流道内的物理参数进行了数值计算。结果表明,大涡模拟能获得比可实现κ-ε模型更精确地结果,同时大涡数值模拟的计算工作量较大
根据上述结论,构建了约束流道的实体物理模型,并采用PIV方法对流道内的流场特性进行实时观测,验证了大涡数值模拟方法的有效性。
(2)软磨粒流的切削机理分析以及固液两相流数值模拟。首先借助于冲蚀理论,分析了影响磨粒加工的主要因素,讨论了软磨粒流加工的机理。接着采用大涡模拟与随机轨道模型相结合的数值计算方法,结合正交实验法,模拟了在多种条件下固液两相流中颗粒的不同运动特性,特别是近壁区的颗粒与壁面的相互作用关系。数值模拟结果表明,流体的速度是流体脉动的主要影响因素,速度越大流体脉动越明显。流体脉动也影响到颗粒的脉动,颗粒脉动还受颗粒直径的影响,颗粒的直径越大其惯性力也越大,受流体脉动的影响相对较小：颗粒的体积含量越多,颗粒之间碰撞的机会也越多,因此颗粒不确定运动的几率也越大。为了进一步验证数值模拟的可行性以及弥补数值模拟的不足之处,流道仍加工成“M”的弯形流道,利用PIV实验系统检测颗粒在流体中的运动情况。实验表明,由于受到湍流的混掺作用,导致颗粒运动偏离主流运动的方向,呈现出与壁面与其它颗粒的碰撞,从而实现颗粒对壁面的有效切除。
(3)化学抛光液的配置与化学抛光实验。采用不同配比的双氧水、草酸、硫酸、尿素等化学成分配置了几种环保型化学抛光液。针对1Cr18Ni9、3Cr2Mo、45#、Q235钢的试件进行了化学抛光实验,并利用分析天平测量质量,计算失重率。实验证明不同的材料在相同化学抛光液中腐蚀程度不同。常温下,抛光5分钟左右,工件表面质量有明显改善。
(4)软磨粒抛光实验。利用软磨粒流精密光整加工试验台,以“M”形流道的45#钢试件为例,进行了软磨粒流抛光实验。研究了流体的速度,磨粒的浓度以及粒径,抛光时间等对材料去除量和表面粗糙度的影响规律。改变所要研究的软磨粒流抛光的某一参数,而使其余的参数保持不变,利用分析太平测量试件的质量,计算去除量；采用TR200手持式粗糙度仪进行测量,采用KEYENCE VW-6000动态分析三维显示系统进行测量工件表面形貌,实验结果证明了软性磨粒流加工方法应用在模具结构化表面光整加工上的可行性和有效性。
(5)通过对软磨粒流抛光作用机理分析,以及参考多相流输运机械中冲蚀破坏模型,结合软磨粒流抛光实验,建立了材料去除率数学模型。
Moulds are the important technological equipment during the process of parts forming. The application field of moulds expanded day after day. With the intense market competition the development trend of moulds appeared large scale, complexity and precision. Accordingly the structured surface such as the groove, the groove, the hole and the slot, that existed in moulds, is difficult for contact processing because of size and shape. In order to solve the problem in reality the method of chemical-aid softness abrasive flow polishing was proposed according to the structured surface of moulds.
The phase of chemical-aid softness abrasive flow polishing can be divided into chemical polishing and softness abrasive flow polishing. Chemical polishing is easy to operated and free of the restriction of the shape and size. In the same time chemical polishing would remove the mechanical nick layer and the stress layer of parts. The surface of the part after the chemical polishing can be machined by the soft abrasive flow more easily, because bonding capability of the surface atoms can be reduced by chemical reactions. Softness abrasive flow polishing could be regarded as the supplement of chemical polishing. It would remove the unsolved metal oxides on the surface and clean the residual chemical liquid. In order to coordinated the two stages the process and the machining mechanism should be researched. The main content in this paper was as the following.
(l)Turbulence characteristics in the process of soft abrasive polishing were researched by the application of numerical simulation. To get detailed information about the turbulence, large eddy simulation and Reynolds-averaged simulation were put into use. The geometry model of numerical simulation was established according to the M shaped flow channel after the analysis of the characteristic of LES and κ-ε model that belonged to Reynolds averaged simulation. Physical parameters in flow channel were gotten by the adoption of Large eddy simulation and κ-ε model in the case of the same initial conditions, boundary conditions and the calculation methods. The results showed that more accurate results could be gotten through large eddy simulation who took more computational workload.
On these conditions, physical model entity of the constrained flow channel was constructed. Then the flow field characteristics was observed with the method of PIV, which proved the effectiveness of the method of LES.
(2)The analysis of cutting mechanism of soft abrasive flow and the numerical simulation of solid-liquid two-phase flow. Firstly based on erosion theory the main factors to affect the particle motion were analyzed. The machining mechanism of soft abrasive flow were discussed. Secondly the different motion characteristics of the particle in the solid-liquid two-phase flow in a variety of conditions were simulated by the adoption of the combination of LES and SPTM, especially the interaction between the wall and the particles in the near-wall region. The numerical simulation results showed that the velocity of the fluid was the main factor of fluid pulsation. The greater the speed, the more obvious the fluid pulsation. The pulsation of the particles was also influenced by the particle diameter. The larger the diameter of the particle, the larger the inertial force. The particle with large diameter was affected by the pulsation little. The more the volume content, the more the chance of collision among particles. Thus the probability of uncertain movement of particles was bigger. The M shaped flow channel was still in use to validate the feasibility of numerical simulation and make up for the deficiency of the numerical simulation. The movement of particles in the fluid could be gotten through observation experimental system. The experiment showed that on account of the blending effect of turbulence particles deviated from the mainstream direction of movement and collided with the wall surface. Thereby the effective resection of the wall surface could be done by particles.
(3)The deployment of the chemical polishing solution and the chemical polishing experiment. Several kinds of chemical polishing liquid were prepared by using different proportion of hydrogen peroxide, oxalic acid, sulfuric acid, urea and other chemical ingredients.1Crl8Ni9,3Cr2Mo,45#and Q235, was used in the chemical polishing experiment. Analytical balance were used to measure the quality of the several steel and mass loss rate could be calculated. The experiment showed that the degree of corrosion of different materials was different in the same chemical polishing solution. At room temperature the surface smoothness of the work piece had a significant improvement after fifteen-minute polishing.
(4)Taking45steel for example, the experiment of soft abrasive flow polishing was done by soft abrasive flow precision machining laboratory bench. The law that some factors, such as the velocity of the fluid, the concentration and the size of particles, polishing time, affected the amount of material removed and the surface roughness was researched. The removal rate was calculated after the quality measurement of the test piece by the analytical balance on condition that only one single parameter of soft abrasive flow polishing changed. The TR200handheld roughness instrument was used for measurement. KEYENCE VW-6000dynamic analysis three-dimension display system was used to measure the surface appearance of work piece. The experimental results showed that applying the method of the soft abrasive flow machining on the structured surface finishing of moulds was feasible and valid.
(5) The mechanism of softness abrasive flow polishing was analyzed. The mathematical model of the material removal rate was established combining the experiment of soft abrasive flow polishing drawing on the erosion failure model of the multiphase flow transport machinery.
化学辅助软磨粒流抛光分为化学抛光、软磨粒流抛光两个阶段。化学抛光工艺简单,操作方便,不受零件形状尺寸的限制,同时化学抛光可除去零件表面的机械损伤层和应力层；化学抛光后的零件表面因为发生了化学反应降低了表面原子的键合能力,提高了软磨粒流抛光的效率。同时,软磨粒流抛光也是化学抛光的一种补充,协助除去表面未溶解的金属氧化物,同时清洗残留的化学液。为了使两个阶段能够起到很好的协调组合作用,需要研究这两个阶段的工艺过程、加工机理等,各章节都仅仅围绕以上需要解决的问题进行展开。本文的主要工作如下：
(1)应用数值模拟技术对软磨粒抛光中流体的湍流特性进行了研究。为了得到洋实的湍流信息,采用大涡数值模拟和雷诺平均模拟两种湍流数值模拟方法进行研究。从理论上,分析了大涡数值模拟和属于雷诺平均模拟的可实现κ-ε模型的特点,建立“M”形的弯形流道为数值模拟的几何模型,在初始条件、边界条件、计算方法都相同的情况下,分别采用大涡模拟和可实现κ-ε模型两种不同的湍流模拟方法分别对流道内的物理参数进行了数值计算。结果表明,大涡模拟能获得比可实现κ-ε模型更精确地结果,同时大涡数值模拟的计算工作量较大
根据上述结论,构建了约束流道的实体物理模型,并采用PIV方法对流道内的流场特性进行实时观测,验证了大涡数值模拟方法的有效性。
(2)软磨粒流的切削机理分析以及固液两相流数值模拟。首先借助于冲蚀理论,分析了影响磨粒加工的主要因素,讨论了软磨粒流加工的机理。接着采用大涡模拟与随机轨道模型相结合的数值计算方法,结合正交实验法,模拟了在多种条件下固液两相流中颗粒的不同运动特性,特别是近壁区的颗粒与壁面的相互作用关系。数值模拟结果表明,流体的速度是流体脉动的主要影响因素,速度越大流体脉动越明显。流体脉动也影响到颗粒的脉动,颗粒脉动还受颗粒直径的影响,颗粒的直径越大其惯性力也越大,受流体脉动的影响相对较小：颗粒的体积含量越多,颗粒之间碰撞的机会也越多,因此颗粒不确定运动的几率也越大。为了进一步验证数值模拟的可行性以及弥补数值模拟的不足之处,流道仍加工成“M”的弯形流道,利用PIV实验系统检测颗粒在流体中的运动情况。实验表明,由于受到湍流的混掺作用,导致颗粒运动偏离主流运动的方向,呈现出与壁面与其它颗粒的碰撞,从而实现颗粒对壁面的有效切除。
(3)化学抛光液的配置与化学抛光实验。采用不同配比的双氧水、草酸、硫酸、尿素等化学成分配置了几种环保型化学抛光液。针对1Cr18Ni9、3Cr2Mo、45#、Q235钢的试件进行了化学抛光实验,并利用分析天平测量质量,计算失重率。实验证明不同的材料在相同化学抛光液中腐蚀程度不同。常温下,抛光5分钟左右,工件表面质量有明显改善。
(4)软磨粒抛光实验。利用软磨粒流精密光整加工试验台,以“M”形流道的45#钢试件为例,进行了软磨粒流抛光实验。研究了流体的速度,磨粒的浓度以及粒径,抛光时间等对材料去除量和表面粗糙度的影响规律。改变所要研究的软磨粒流抛光的某一参数,而使其余的参数保持不变,利用分析太平测量试件的质量,计算去除量；采用TR200手持式粗糙度仪进行测量,采用KEYENCE VW-6000动态分析三维显示系统进行测量工件表面形貌,实验结果证明了软性磨粒流加工方法应用在模具结构化表面光整加工上的可行性和有效性。
(5)通过对软磨粒流抛光作用机理分析,以及参考多相流输运机械中冲蚀破坏模型,结合软磨粒流抛光实验,建立了材料去除率数学模型。
Moulds are the important technological equipment during the process of parts forming. The application field of moulds expanded day after day. With the intense market competition the development trend of moulds appeared large scale, complexity and precision. Accordingly the structured surface such as the groove, the groove, the hole and the slot, that existed in moulds, is difficult for contact processing because of size and shape. In order to solve the problem in reality the method of chemical-aid softness abrasive flow polishing was proposed according to the structured surface of moulds.
The phase of chemical-aid softness abrasive flow polishing can be divided into chemical polishing and softness abrasive flow polishing. Chemical polishing is easy to operated and free of the restriction of the shape and size. In the same time chemical polishing would remove the mechanical nick layer and the stress layer of parts. The surface of the part after the chemical polishing can be machined by the soft abrasive flow more easily, because bonding capability of the surface atoms can be reduced by chemical reactions. Softness abrasive flow polishing could be regarded as the supplement of chemical polishing. It would remove the unsolved metal oxides on the surface and clean the residual chemical liquid. In order to coordinated the two stages the process and the machining mechanism should be researched. The main content in this paper was as the following.
(l)Turbulence characteristics in the process of soft abrasive polishing were researched by the application of numerical simulation. To get detailed information about the turbulence, large eddy simulation and Reynolds-averaged simulation were put into use. The geometry model of numerical simulation was established according to the M shaped flow channel after the analysis of the characteristic of LES and κ-ε model that belonged to Reynolds averaged simulation. Physical parameters in flow channel were gotten by the adoption of Large eddy simulation and κ-ε model in the case of the same initial conditions, boundary conditions and the calculation methods. The results showed that more accurate results could be gotten through large eddy simulation who took more computational workload.
On these conditions, physical model entity of the constrained flow channel was constructed. Then the flow field characteristics was observed with the method of PIV, which proved the effectiveness of the method of LES.
(2)The analysis of cutting mechanism of soft abrasive flow and the numerical simulation of solid-liquid two-phase flow. Firstly based on erosion theory the main factors to affect the particle motion were analyzed. The machining mechanism of soft abrasive flow were discussed. Secondly the different motion characteristics of the particle in the solid-liquid two-phase flow in a variety of conditions were simulated by the adoption of the combination of LES and SPTM, especially the interaction between the wall and the particles in the near-wall region. The numerical simulation results showed that the velocity of the fluid was the main factor of fluid pulsation. The greater the speed, the more obvious the fluid pulsation. The pulsation of the particles was also influenced by the particle diameter. The larger the diameter of the particle, the larger the inertial force. The particle with large diameter was affected by the pulsation little. The more the volume content, the more the chance of collision among particles. Thus the probability of uncertain movement of particles was bigger. The M shaped flow channel was still in use to validate the feasibility of numerical simulation and make up for the deficiency of the numerical simulation. The movement of particles in the fluid could be gotten through observation experimental system. The experiment showed that on account of the blending effect of turbulence particles deviated from the mainstream direction of movement and collided with the wall surface. Thereby the effective resection of the wall surface could be done by particles.
(3)The deployment of the chemical polishing solution and the chemical polishing experiment. Several kinds of chemical polishing liquid were prepared by using different proportion of hydrogen peroxide, oxalic acid, sulfuric acid, urea and other chemical ingredients.1Crl8Ni9,3Cr2Mo,45#and Q235, was used in the chemical polishing experiment. Analytical balance were used to measure the quality of the several steel and mass loss rate could be calculated. The experiment showed that the degree of corrosion of different materials was different in the same chemical polishing solution. At room temperature the surface smoothness of the work piece had a significant improvement after fifteen-minute polishing.
(4)Taking45steel for example, the experiment of soft abrasive flow polishing was done by soft abrasive flow precision machining laboratory bench. The law that some factors, such as the velocity of the fluid, the concentration and the size of particles, polishing time, affected the amount of material removed and the surface roughness was researched. The removal rate was calculated after the quality measurement of the test piece by the analytical balance on condition that only one single parameter of soft abrasive flow polishing changed. The TR200handheld roughness instrument was used for measurement. KEYENCE VW-6000dynamic analysis three-dimension display system was used to measure the surface appearance of work piece. The experimental results showed that applying the method of the soft abrasive flow machining on the structured surface finishing of moulds was feasible and valid.
(5) The mechanism of softness abrasive flow polishing was analyzed. The mathematical model of the material removal rate was established combining the experiment of soft abrasive flow polishing drawing on the erosion failure model of the multiphase flow transport machinery.
引文
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