花岗石异型面成形加工及材料断裂去除机理研究
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摘要
用金刚石成型刀具对花岗石异型制品进行成形加工,是一种经济高效的石材加工方式,被企业广泛采用。然而由于成型刀具曲线复杂,切削过程中各切削点工艺参数均不一致,金刚石颗粒受力不均匀,无法进行定量的理论研究,导致在此领域的理论研究相对滞后,生产中许多加工问题得不到及时解决。
实验采用先进数控加工中心设备和金刚石成型铣刀,以石岛红花岗石大圆边直位花线成形切削的实验过程为研究对象,对花岗石成形切削参数与切削力之间的相互关系进行了深入分析,并从断裂的角度对花岗石成形切削过程中裂纹的产生以及扩展进行分析,对花岗石异型制品的加工过程进行分类与分析。
课题采用实验测量分析与数学理论建模相结合的方法进行数据分析与研究。针对成形加工阶段不同异型制品采用加工工艺、设备、工序和加工要求的不同,对花岗石异型制品成形加工进行分析,提出了高效加工的切削参数水平的建议取值。通过在设定的花岗石成形加工工艺参数下进行切削实验,测量得到不同参数下的切削力信息,分析了石材去除率与各向切削力的变化规律。研究了切削参数中刀具转速n、进给速度V_f、切削深度a_p对石材去除率和切削力的影响程度。
通过实验建立了金刚石成型刀具在异型制品成形加工中的切削母线函数模型;建立了成型刀具切削花岗石的材料去除率理论公式;根据切削面的几何特点建立了切削接触面、刀具接触弧长与金刚石单颗粒切削厚度的函数模型;建立了顺铣、逆铣条件下,切削条件与切削力之间的数学模型。为详细研究金刚石颗粒在成形切削中各部位的非均匀受力分析与颗粒断裂脱落机理提供了理论基础。
课题的研究为花岗石异型制品成形加工的工艺方式提供了合理化参考,为成型刀具在花岗石成形加工中的金刚石颗粒不均匀脱落、破损的定量研究提供理论依据。其研究成果不仅对花岗石异型制品的生产具有指导意义,也将对花岗石异型制品加工的理论研究产生深远影响。
It's an economical and efficiency technical way with to machine special-shaped product of granite with diamond shaped tools, which is widely used by stone enterprises. However, due to complex curves molding tool, the process of cutting the point of cutting parameters is inconsistent, the cutting force of the diamond grain is inhomogeneous. So we can't to go quantitative theoretical research, resulting to the theoretical research in this field is seriously lagged behind, the problem in production process isn't be timely resolved.
We take advanced machining center equipment, use a diamond shaped milling cutter, to machine 1/4 circular surface of straight-line forming of special-shaped granite named Shidao Red as the research object. In the process of product processing Classification and analysis of a detailed introduction of fracture mechanics of ideas, granite forming the cutting process and the formation of cracks in the expansion of the analysis of the cutting parameters and granite forming the relationship between the cutting force conducted an in-depth analysis.
We use the experimental analysis and mathematical modeling theory to research. First of all, we clearly put forward the special-shaped granite products in the processing of different types of efficient processing definition. Special-shaped granite of the process carried out a detailed analysis of different stages of processing for forming the processing methods, equipment and processing technology, in accordance with cutting depth and the complexity of the shape of processing the different products forming different types of granite processing for analysis. Secondly, we analysis the inadequacy of the traditional parameters of granite processing and propose the processing efficient level of parameters value.
By setting granite forming process parameters under cutting experiments, we measured processing under different parameters of the cutting force information, so we analysis the change of stone removal and the cutting force with the cutting tool parameters speed n, feed rate V_f, depth of cut a_p.
We take diamond shaped milling cutter as a series of very thin films of diamond saw blades. We first established a special-shaped diamond shaped milling in the processing of products forming the cutting lines mathematical model shows that the molding Cutting bus mathematical function; Forming the establishment of a diamond cutting tool material removal granite theoretical formula and simplified formula, the formula is specified through the granite material removal rate and cutting parameters of the mathematical relationship between the light of the geometric characteristics of cutting-established Cutting contact with the mathematical analysis of the calculation model. For a detailed study of diamond particles forming in various parts of cutting non-uniform particle analysis and fracture mechanism shedding provide a theoretical basis.
The study of this subject provide a rationalization of reference for different types of granite forming processing products, and provide a theoretical basis for prototyping tool in the processing of granite forming the diamond particles shed, damaged quantitative study. The research results not only have practical significance as a guide to the manufacture of different types of granite, At the same time, the investigative thinking and ways in this paper would produce far-reaching influence to theory of machining special-shaped stone.
实验采用先进数控加工中心设备和金刚石成型铣刀,以石岛红花岗石大圆边直位花线成形切削的实验过程为研究对象,对花岗石成形切削参数与切削力之间的相互关系进行了深入分析,并从断裂的角度对花岗石成形切削过程中裂纹的产生以及扩展进行分析,对花岗石异型制品的加工过程进行分类与分析。
课题采用实验测量分析与数学理论建模相结合的方法进行数据分析与研究。针对成形加工阶段不同异型制品采用加工工艺、设备、工序和加工要求的不同,对花岗石异型制品成形加工进行分析,提出了高效加工的切削参数水平的建议取值。通过在设定的花岗石成形加工工艺参数下进行切削实验,测量得到不同参数下的切削力信息,分析了石材去除率与各向切削力的变化规律。研究了切削参数中刀具转速n、进给速度V_f、切削深度a_p对石材去除率和切削力的影响程度。
通过实验建立了金刚石成型刀具在异型制品成形加工中的切削母线函数模型;建立了成型刀具切削花岗石的材料去除率理论公式;根据切削面的几何特点建立了切削接触面、刀具接触弧长与金刚石单颗粒切削厚度的函数模型;建立了顺铣、逆铣条件下,切削条件与切削力之间的数学模型。为详细研究金刚石颗粒在成形切削中各部位的非均匀受力分析与颗粒断裂脱落机理提供了理论基础。
课题的研究为花岗石异型制品成形加工的工艺方式提供了合理化参考,为成型刀具在花岗石成形加工中的金刚石颗粒不均匀脱落、破损的定量研究提供理论依据。其研究成果不仅对花岗石异型制品的生产具有指导意义,也将对花岗石异型制品加工的理论研究产生深远影响。
It's an economical and efficiency technical way with to machine special-shaped product of granite with diamond shaped tools, which is widely used by stone enterprises. However, due to complex curves molding tool, the process of cutting the point of cutting parameters is inconsistent, the cutting force of the diamond grain is inhomogeneous. So we can't to go quantitative theoretical research, resulting to the theoretical research in this field is seriously lagged behind, the problem in production process isn't be timely resolved.
We take advanced machining center equipment, use a diamond shaped milling cutter, to machine 1/4 circular surface of straight-line forming of special-shaped granite named Shidao Red as the research object. In the process of product processing Classification and analysis of a detailed introduction of fracture mechanics of ideas, granite forming the cutting process and the formation of cracks in the expansion of the analysis of the cutting parameters and granite forming the relationship between the cutting force conducted an in-depth analysis.
We use the experimental analysis and mathematical modeling theory to research. First of all, we clearly put forward the special-shaped granite products in the processing of different types of efficient processing definition. Special-shaped granite of the process carried out a detailed analysis of different stages of processing for forming the processing methods, equipment and processing technology, in accordance with cutting depth and the complexity of the shape of processing the different products forming different types of granite processing for analysis. Secondly, we analysis the inadequacy of the traditional parameters of granite processing and propose the processing efficient level of parameters value.
By setting granite forming process parameters under cutting experiments, we measured processing under different parameters of the cutting force information, so we analysis the change of stone removal and the cutting force with the cutting tool parameters speed n, feed rate V_f, depth of cut a_p.
We take diamond shaped milling cutter as a series of very thin films of diamond saw blades. We first established a special-shaped diamond shaped milling in the processing of products forming the cutting lines mathematical model shows that the molding Cutting bus mathematical function; Forming the establishment of a diamond cutting tool material removal granite theoretical formula and simplified formula, the formula is specified through the granite material removal rate and cutting parameters of the mathematical relationship between the light of the geometric characteristics of cutting-established Cutting contact with the mathematical analysis of the calculation model. For a detailed study of diamond particles forming in various parts of cutting non-uniform particle analysis and fracture mechanism shedding provide a theoretical basis.
The study of this subject provide a rationalization of reference for different types of granite forming processing products, and provide a theoretical basis for prototyping tool in the processing of granite forming the diamond particles shed, damaged quantitative study. The research results not only have practical significance as a guide to the manufacture of different types of granite, At the same time, the investigative thinking and ways in this paper would produce far-reaching influence to theory of machining special-shaped stone.
引文
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2 张进生,王日君,王志.饰面石材加工技术.北京:化学工业出版社,2006
3 张政梅.花岗石异型面加工技术与工具磨破损实验研究.山东大学硕士学位论文.2006:7-8
4 王道林.断裂力学在金属切削中的应用.机械制造与研究.2003,(6):55-56
5 李远,黄辉,于怡青,徐西鹏.切磨过程中花岗石去除机理研究.矿物学报.2001,21(3):401-405
6 Xipeng Xu,Jianyun Shen.Wear mechanism of diamond-alloy composite for sawing of granites.Acta Materiae Composite Sinica.1998,15(1):101-107
7 徐西鹏,沈剑云,黄辉.实现花岗石高效锯切的关键因素分析.机械工程学报.1998,34(1):104-110
8 Huang.H,Xu.X.P.Interfacial interactions between diamond disk and granite during vertical spindle grinding.Wear.2004,256(6):623-629
9 S.Turchetta,L.Carrino,W.Polini.CVD diamond insert in stone cutting.Diamond and Related Materials.2005,14:641-645
10 Y.C.Fu,H.J.Xu,J.H.Xu.Optimization design of grinding wheel topography for high efficiency grinding.Journal of Materials Processing Technology.2002,129(1-3):118-122
11 K.Fathima,A.Senthil Kumar,M.Rahman,H.S.Lim.A study on wear mechanism and wear reduction strategies in grinding wheels used for ELID grinding.Wear.2003,254(12):1247-1255
12 Albert.J.Shih,William.I.Clark,Jeffrey.L.Akemon.Wear of the blade diamond tools in truing vitreous bond grinding wheels Part Ⅱ.Truing and grinding forces and wear mechanism.Wear.2001,250:593-603
13 S.Y.Luo,Y.S.Liao.Study of the behaviour of diamond saw-blades in stone processing.Journal of Material Processing Technology.1995,51:296-308
14 K.W.Lee,P.K.Wong,J.H.Zhang.Study on the grinding of advanced ceramics with slotted diamond wheels.Journal of Materials Processing Technology.2000,100:230-235
15 李远.锯切花岗石过程中的力和能量特征.华侨大学硕士学位论文.2000,63-70
16 初晓飞.大切深锯切中力对金刚石节块状态的依赖性研究.华侨大学硕士学位论文.2004,37-45
17 Hagiwara.Shinsaku,Iwata.Shuji,Obikawa.Toshiyuki,Usui.Eiji.Study on the transition process of diamond grain shape in stone grinding.Journal of Materials Processing Technology.1997,63(1-3):892-896
18 Hans Kurt Tonshoff,Friemuth Thomas.In-process dressing of fine diamond wheels for tool grinding.Precision Engineering.2000,24(1):58-61
19 李远.花岗石超大切深锯切机理与技术研究.华侨大学博士学位论文.2004,88-102
20 徐西鹏,骆灿彬.锯切用量对花岗石可锯切性影响的试验研究.中国机械工程.1997,8(6):81-83
21 徐西鹏.岩石材料的金刚石锯切研究进展.机械工程学报.2003,39(9):17-22
22 魏庆同,龚俊.开发裂纹功利的力学与工程进展.兰州工业高等专科学校学报.1994,1(1):9-14
23 郭学彬,肖正学,陈晓玲.石材爆破的断裂控制原理及措施.爆破.1997,14(2):13-16
24 杨杰,严荣荫,陈厚伦,谭世同.中国石材.中国建材工业出版社,1994
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27 李伯民.现代磨削技术.北京:机械工业出版社,2004
28 艾兴.高速切削加工技术.北京:国防工业出版社,2003
29 Xing Ai.Development and Application of High-Speed Machining Technology.The 11~(th)International Manufacturing Conference in China.2004:18-30
30 艾兴.高效加工技术及其应用研究.中国工程科学.2000,2(11):40-51
31 Polini.W.Turchetta.S.Force and specific energy in stone cutting by diamond mill.International Journal of Machine Tools and Manufacture.2004,44(11):1189-1196
32 Polini.W,Turchetta.S.To characterize diamond mill wear.Wear.2003,255(7-12):1414-1420
33 Carrino.L,Polini.W,Turchetta.S.Wear progression of diamond mills.Diamond and Related Materials.2003,12(3-7):728-732
34 Polini.W,Turchetta.S.Test protocol for micro-geometric wear of sintered diamond tools.Wear.2004,257(3-4):246-256
35 F.Norihiro,M.Junichi.Development of high-performance CBN and diamond grinding wheels for high-speed grinding.New Diamond and Frontier Carbon Technology.2005,(15)4:173-180
36 Xipeng Xu.Experimental study on temperatures and energy partition at the diamond-granite interface in grinding.Tribology International.2001,34(6):419-426
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58 王智慧.金刚石吃入岩石深度公式的理论推导及存在问题探讨.石材.2000,4:30-32
2 张进生,王日君,王志.饰面石材加工技术.北京:化学工业出版社,2006
3 张政梅.花岗石异型面加工技术与工具磨破损实验研究.山东大学硕士学位论文.2006:7-8
4 王道林.断裂力学在金属切削中的应用.机械制造与研究.2003,(6):55-56
5 李远,黄辉,于怡青,徐西鹏.切磨过程中花岗石去除机理研究.矿物学报.2001,21(3):401-405
6 Xipeng Xu,Jianyun Shen.Wear mechanism of diamond-alloy composite for sawing of granites.Acta Materiae Composite Sinica.1998,15(1):101-107
7 徐西鹏,沈剑云,黄辉.实现花岗石高效锯切的关键因素分析.机械工程学报.1998,34(1):104-110
8 Huang.H,Xu.X.P.Interfacial interactions between diamond disk and granite during vertical spindle grinding.Wear.2004,256(6):623-629
9 S.Turchetta,L.Carrino,W.Polini.CVD diamond insert in stone cutting.Diamond and Related Materials.2005,14:641-645
10 Y.C.Fu,H.J.Xu,J.H.Xu.Optimization design of grinding wheel topography for high efficiency grinding.Journal of Materials Processing Technology.2002,129(1-3):118-122
11 K.Fathima,A.Senthil Kumar,M.Rahman,H.S.Lim.A study on wear mechanism and wear reduction strategies in grinding wheels used for ELID grinding.Wear.2003,254(12):1247-1255
12 Albert.J.Shih,William.I.Clark,Jeffrey.L.Akemon.Wear of the blade diamond tools in truing vitreous bond grinding wheels Part Ⅱ.Truing and grinding forces and wear mechanism.Wear.2001,250:593-603
13 S.Y.Luo,Y.S.Liao.Study of the behaviour of diamond saw-blades in stone processing.Journal of Material Processing Technology.1995,51:296-308
14 K.W.Lee,P.K.Wong,J.H.Zhang.Study on the grinding of advanced ceramics with slotted diamond wheels.Journal of Materials Processing Technology.2000,100:230-235
15 李远.锯切花岗石过程中的力和能量特征.华侨大学硕士学位论文.2000,63-70
16 初晓飞.大切深锯切中力对金刚石节块状态的依赖性研究.华侨大学硕士学位论文.2004,37-45
17 Hagiwara.Shinsaku,Iwata.Shuji,Obikawa.Toshiyuki,Usui.Eiji.Study on the transition process of diamond grain shape in stone grinding.Journal of Materials Processing Technology.1997,63(1-3):892-896
18 Hans Kurt Tonshoff,Friemuth Thomas.In-process dressing of fine diamond wheels for tool grinding.Precision Engineering.2000,24(1):58-61
19 李远.花岗石超大切深锯切机理与技术研究.华侨大学博士学位论文.2004,88-102
20 徐西鹏,骆灿彬.锯切用量对花岗石可锯切性影响的试验研究.中国机械工程.1997,8(6):81-83
21 徐西鹏.岩石材料的金刚石锯切研究进展.机械工程学报.2003,39(9):17-22
22 魏庆同,龚俊.开发裂纹功利的力学与工程进展.兰州工业高等专科学校学报.1994,1(1):9-14
23 郭学彬,肖正学,陈晓玲.石材爆破的断裂控制原理及措施.爆破.1997,14(2):13-16
24 杨杰,严荣荫,陈厚伦,谭世同.中国石材.中国建材工业出版社,1994
25 李贺.岩石断裂力学.重庆:重庆大学出版社,1988
26 孙春华,尚广庆.脆硬材料加工机理的研究.金刚石与磨料磨具工程.2002,4(130):51-53
27 李伯民.现代磨削技术.北京:机械工业出版社,2004
28 艾兴.高速切削加工技术.北京:国防工业出版社,2003
29 Xing Ai.Development and Application of High-Speed Machining Technology.The 11~(th)International Manufacturing Conference in China.2004:18-30
30 艾兴.高效加工技术及其应用研究.中国工程科学.2000,2(11):40-51
31 Polini.W.Turchetta.S.Force and specific energy in stone cutting by diamond mill.International Journal of Machine Tools and Manufacture.2004,44(11):1189-1196
32 Polini.W,Turchetta.S.To characterize diamond mill wear.Wear.2003,255(7-12):1414-1420
33 Carrino.L,Polini.W,Turchetta.S.Wear progression of diamond mills.Diamond and Related Materials.2003,12(3-7):728-732
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