旋转功率超声珩磨加工机理及工艺实验研究
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摘要
旋转功率超声加工是工具在作超声振动的同时附加了旋转运动。本文主要研究采用固着磨料的旋转功率超声波加工材料的去除机理,阐述了旋转功率超声加工的材料去除模式,提出了延性去除模式。并利用晶体位错原理,解释了碎屑产生的机理。深入分析了纵向功率超声振动珩磨的运动速度合成,推导出了基于动点合成理论的纵向功率超声振动合成速度公式,并确立了更加适合加工实际的临界速度。针对尖锐形和球形磨粒的材料去除机理进行了深入的探讨,建立了超声振动珩磨时材料的去除率数学模型。在此基础上,利用超声珩磨设备对ф47mm的CrMoCu耐磨合金铸铁摩托车缸套进行工艺实验研究,对磨料粒度、机床圆周速度、往复速度、超声波频率、振幅和珩磨油石的工作压力等参数进行了分析,得出了旋转功率超声珩磨加工的工艺参数,对旋转功率超声珩磨加工的实际应用具有一定的指导意义。
The rotary ultrasonic machining (RUM) is that the tool is appended a revolution motion when it does ultrasonic vibration. This paper studies mainly that characteristic removal mechanism of the adherence abrasive powder, expanding the model material removal and putting forward a method of ductile crack. And using crystal dislocation mechanism, the mechanism of detrital material is explained. Though analyzing the composing speed RUM honing of lengthwise movement, we have deduced that the formula composing speed based on the moving point composes theory. The critical velocity is established which is especially fit to process reality. The paper also discusses the characteristic removal mechanism of angular abrasive and globoid abrasive. On the basis , the paper studies processing experiment onф47mm motorcycle cylinder of CrMoCu alloy cast iron. Through analyzing parameters such as circumference speed of machine tool, the speed moving back and forth, ultrasonic frequency, amplitude and honing oilstone actuating pressure etc. It has obtained processing parameters of RUM honing, and has surpassed the actual application that RUM honing processes to revolution power having certain guiding significance.
The rotary ultrasonic machining (RUM) is that the tool is appended a revolution motion when it does ultrasonic vibration. This paper studies mainly that characteristic removal mechanism of the adherence abrasive powder, expanding the model material removal and putting forward a method of ductile crack. And using crystal dislocation mechanism, the mechanism of detrital material is explained. Though analyzing the composing speed RUM honing of lengthwise movement, we have deduced that the formula composing speed based on the moving point composes theory. The critical velocity is established which is especially fit to process reality. The paper also discusses the characteristic removal mechanism of angular abrasive and globoid abrasive. On the basis , the paper studies processing experiment onф47mm motorcycle cylinder of CrMoCu alloy cast iron. Through analyzing parameters such as circumference speed of machine tool, the speed moving back and forth, ultrasonic frequency, amplitude and honing oilstone actuating pressure etc. It has obtained processing parameters of RUM honing, and has surpassed the actual application that RUM honing processes to revolution power having certain guiding significance.
引文
[1]Eduardo Tomanik . Friction and wear bench tests of different engine liner surface finishes , Tribology International, In Press, Corrected Proof, Available online 28 January 2008
[2]Joan L. Huffman .Educating Surgeons for the New Golden Hours: Honing the Skills of Palliative Care Surgical Clinics of North America, Volume 85, Issue 2, April 2005, Pages 383-391
[3]K. Oobayashi, K. Irie and F. Honda. Producing gear teeth with high form accuracy and fine surface finish using water-lubricated chemical reactions , Tribology International, Volume 38, Issue 3, March 2005, Pages 243-248
[4]Hargreaves DJ, Scott W. The effect of honing on the frictional resistance of cylinder liners, Society of Manufacturing Engineers, SME paper MR98-215, 1998
[5]G. Burkhard , F. Rehsteiner and B. Schumacher. High Efficiency Abrasive Tool for Honing,CIRP Annals - Manufacturing Technology, Volume 51, Issue 1, 2002, Pages 271-274
[6]Ottó Szabó. Optimisation of technology and “quasi honing” of polygon bores, Journal of Materials Processing Technology, Volume 119, Issues 1-3, 20 December 2001, Pages 117-121
[7] 王爱玲,祝锡晶,吴秀玲.功率超声振动加工技术.北京:国防工业出版社,2006
[8] 郑文虎.精米切削与光整加工技术.北京:机械工业出版社,2006.1
[9] 曹凤国.超声加工技术.北京:化学工业出版社,2005.1
[10] 隈部淳一郎.精密加工——振动切削基础和应用(中译本).北京:机械工业出版社,1985
[11] 〔德). Konig. Wilfried.超声波加工过程的控制 Maschinenmarkt,1993,99(33)
[12] Komaraiah, M.A.Study on the influence of workpiece properties in ultrasonic maching Reddy.P.Narasimha, int J Mach Tools Manuf.v33 n3 jun 1993 P495~505
[13] Hanbing Xu .Effects of ultrasonic vibration on degassing of aluminum alloys. Materials Science and Engineering .A, Volume 473, Issues 1-2, 25 January 2008, Pages 96-104
[14] 祝锡晶.超声光整加工及表面成型技术.北京:中国科学文化出版社,2005.11
[15] 祝锡晶.功率超声珩磨在发动机缸套光整加工中的应用研究.兵工学报,2002.03
[16] 祝锡晶.超声珩磨加工.机械工艺师, 2001.07,35-36
[17] 张于贤,王红等.关于动点的速度合成定理的一个推论.桂林电子工业学院学报,2002.10,64-66
[18] Xiaojun Xian.Study on the Compound Multifrequency Ultrasonic Transducer in Flexural Vibration . Ultrasonics .Available online 8, January 2008
[19] G.Ya,H.W.Qin,Analysis of the rotary ultrasonic machining mechanism.Journal of Materials Processing Technology,2002(129),182-185
[20] 林 晶,顾立志等.超声波振动切削剪切应力的研究.佳木斯大学学报,2001.12,337-339
[21] 牛国玲, 赵黎杰等.振动切削机理的研究状况. 佳木斯大学学报,2005.07,479-482
[22] (日)太田和羲著,刘阳春译.超声波振动切削加工技术.国外金属加工.2001(4),25-28.
[23] 殷宝麟,韩荣第.振动切削机理研究.机械研究与应用.2004.10,41-43
[24] X. S. Zhu.Experimental and theoretical research on ‘local resonance’ in an ultrasonic honing system. Journal of Materials Processing Technology, Volume 129, Issues 1-3, 11 October 2002, Pages 207-211
[25] 轧钢,秦伟华等.旋转超声波加工的实验研究.航空制造技术,2000.06
[26] 郭东明,王晓明等.面向快速制造的特种加工技术.中国机械工程,2000.12
[27] 彭海,张敏等.混合磨料珩磨油石的磨削性能研究.金刚石与磨料磨具工程,2006.08,50-54
[28] Suzuki K,Tochinal H.A new grinding method forcermics using a biaxially visrated nonrotational.Annals of the CIRP,1993.01,375-378
[29] Brown N J.Some speculations on the mechanisms of abrasive grinding and polishing. Annals of the CIRP,1993.01,421-424
[30] 李伯民,赵波.现代磨削技术.北京:机械工业出版社,2003
[31] Boogert R M, Kals H J J. Tool paths and cutting technology in computer-aided processplanning.Int J Adv Manuf Technol, 1997(4).
[32] Gilmore.Randy.Ultrasonic machining.A Case Study.Mater Process Technol v28 n1-2 sep 1991 7th International conference on computer-Aided production.Enginering Cookeville TN, USA.Aug 13-14 1991, P139-148
[33] Zhu Xijing.Study on the Technology of New Ultrasonic Honing.Key Engineering Materials, Vols. 202-203(2001), 407-410, 2001 Trans Tech Publications, Switzerland (被 SCI光盘版收录)
[34] Zhu Xijing.Study on the Technology and the New Ultrasonic Honing.The 11th Grinding Conference in China, Huaqiao university, Quanzhou 2001.6(被 EI 光盘版收录)
[35] Zhu Xijing. Research on the New Technology and system of Ultrasonic Honing. The 10th international Manufacturing Conference in China, Xiamen, China, October 2002.
[36] 卢泽生.精密超声振动切削频率对切削力影响规律的研究与仿真. 航空精密制造技术.2006.05
[37] 祝锡晶.功率超声换能器的工程设计原理及方法.山西机械,1999 增刊:4-6
[38] 苏达智.影响珩磨精度的各种要素分析.新技术/新工艺,1989(2)
[39] 祝锡晶.功率超声珩磨缸套加工中谐振系统的试验研究.中国机械工程,2002.09,727-730
[40] 辛志杰.超声珩磨振动系统动态设计.组合机床与自动化加工技术, 2006.06
[41] 李祥林,薛万夫等.振动切削及其在机械加工中的应用.北京:北京科学技术出版社,1985
[42] 张洪丽.超声振动磨削运动学分析.制造技术与机床, 2006.06
[43] Zhao Bo.Surface characteristics in the ultrasonic ductile honing of ZrO2 ceramics using coarse grits. Journal of Materials Processing Technology, Volume 123, Issue 1, 10 April 2002, Pages 54-60
[44] 邝广镛.JHT 系列精密金刚石珩磨头及其应用.机械制造, 1992(9)
[45] Herbst L, et al. Targeting diesel engine efficiency, Industrial Laser Solutions, October 2004
[46] Hargreaves DJ, Scott W. The effect of honing on the frictional resistance of cylinderliners. Society of Manufacturing Engineers, SME paper MR98-215, 1998.
[47] Robota A, Zwein F. Influence of cylinder bore topography on the oil consumption and particulate emissions of a DI TCI diesel engine. MTZ 60 (1999, vol. 4), 1999
[48] Klink U, Flores G. New technologies of honing. Society of Manufacturing Engineers, ASME paper MR98-210, 1998
[49] Sato O, et al. Improvement of piston lubrication in a diesel engine by means of cylinder surface roughness. SAE paper 2004-01-0604
[50] Jocsak J, et al. The effects of cylinder liner finish on piston ring-pack friction. ASME paper ICEF2004-952, 2004
[51]徐可伟.超声振动在精密切削中的应用[J] .新技术·新工艺,2001(3):63-64
[52]陈斌,徐可伟.超声波振动切削薄壁镜筒零件的研究[J] .机械工程师.2001(1):40-42
[53]焦光明,.超声振动切削加工精度的试验研究[J] .电加工,1991(5):15-19
[54]T. Aoyama, I. Inasaki, Development of a Robot System for Metal Molds Polishing, Vol. XXI, Department of Mechanical Engineering, Keio University, Yokohama, 1993, pp. 295–301
[55]J. Brevick, Automated die and mold finishing: an experimental study of short stroke honing, in: Proceedings of the 20th NAMARA International Conference, USA, 1992
[56] B. Nowicki, The new method of free form surface honing, Ann. CIRP 42 (1) (1993)
[2]Joan L. Huffman .Educating Surgeons for the New Golden Hours: Honing the Skills of Palliative Care Surgical Clinics of North America, Volume 85, Issue 2, April 2005, Pages 383-391
[3]K. Oobayashi, K. Irie and F. Honda. Producing gear teeth with high form accuracy and fine surface finish using water-lubricated chemical reactions , Tribology International, Volume 38, Issue 3, March 2005, Pages 243-248
[4]Hargreaves DJ, Scott W. The effect of honing on the frictional resistance of cylinder liners, Society of Manufacturing Engineers, SME paper MR98-215, 1998
[5]G. Burkhard , F. Rehsteiner and B. Schumacher. High Efficiency Abrasive Tool for Honing,CIRP Annals - Manufacturing Technology, Volume 51, Issue 1, 2002, Pages 271-274
[6]Ottó Szabó. Optimisation of technology and “quasi honing” of polygon bores, Journal of Materials Processing Technology, Volume 119, Issues 1-3, 20 December 2001, Pages 117-121
[7] 王爱玲,祝锡晶,吴秀玲.功率超声振动加工技术.北京:国防工业出版社,2006
[8] 郑文虎.精米切削与光整加工技术.北京:机械工业出版社,2006.1
[9] 曹凤国.超声加工技术.北京:化学工业出版社,2005.1
[10] 隈部淳一郎.精密加工——振动切削基础和应用(中译本).北京:机械工业出版社,1985
[11] 〔德). Konig. Wilfried.超声波加工过程的控制 Maschinenmarkt,1993,99(33)
[12] Komaraiah, M.A.Study on the influence of workpiece properties in ultrasonic maching Reddy.P.Narasimha, int J Mach Tools Manuf.v33 n3 jun 1993 P495~505
[13] Hanbing Xu .Effects of ultrasonic vibration on degassing of aluminum alloys. Materials Science and Engineering .A, Volume 473, Issues 1-2, 25 January 2008, Pages 96-104
[14] 祝锡晶.超声光整加工及表面成型技术.北京:中国科学文化出版社,2005.11
[15] 祝锡晶.功率超声珩磨在发动机缸套光整加工中的应用研究.兵工学报,2002.03
[16] 祝锡晶.超声珩磨加工.机械工艺师, 2001.07,35-36
[17] 张于贤,王红等.关于动点的速度合成定理的一个推论.桂林电子工业学院学报,2002.10,64-66
[18] Xiaojun Xian.Study on the Compound Multifrequency Ultrasonic Transducer in Flexural Vibration . Ultrasonics .Available online 8, January 2008
[19] G.Ya,H.W.Qin,Analysis of the rotary ultrasonic machining mechanism.Journal of Materials Processing Technology,2002(129),182-185
[20] 林 晶,顾立志等.超声波振动切削剪切应力的研究.佳木斯大学学报,2001.12,337-339
[21] 牛国玲, 赵黎杰等.振动切削机理的研究状况. 佳木斯大学学报,2005.07,479-482
[22] (日)太田和羲著,刘阳春译.超声波振动切削加工技术.国外金属加工.2001(4),25-28.
[23] 殷宝麟,韩荣第.振动切削机理研究.机械研究与应用.2004.10,41-43
[24] X. S. Zhu.Experimental and theoretical research on ‘local resonance’ in an ultrasonic honing system. Journal of Materials Processing Technology, Volume 129, Issues 1-3, 11 October 2002, Pages 207-211
[25] 轧钢,秦伟华等.旋转超声波加工的实验研究.航空制造技术,2000.06
[26] 郭东明,王晓明等.面向快速制造的特种加工技术.中国机械工程,2000.12
[27] 彭海,张敏等.混合磨料珩磨油石的磨削性能研究.金刚石与磨料磨具工程,2006.08,50-54
[28] Suzuki K,Tochinal H.A new grinding method forcermics using a biaxially visrated nonrotational.Annals of the CIRP,1993.01,375-378
[29] Brown N J.Some speculations on the mechanisms of abrasive grinding and polishing. Annals of the CIRP,1993.01,421-424
[30] 李伯民,赵波.现代磨削技术.北京:机械工业出版社,2003
[31] Boogert R M, Kals H J J. Tool paths and cutting technology in computer-aided processplanning.Int J Adv Manuf Technol, 1997(4).
[32] Gilmore.Randy.Ultrasonic machining.A Case Study.Mater Process Technol v28 n1-2 sep 1991 7th International conference on computer-Aided production.Enginering Cookeville TN, USA.Aug 13-14 1991, P139-148
[33] Zhu Xijing.Study on the Technology of New Ultrasonic Honing.Key Engineering Materials, Vols. 202-203(2001), 407-410, 2001 Trans Tech Publications, Switzerland (被 SCI光盘版收录)
[34] Zhu Xijing.Study on the Technology and the New Ultrasonic Honing.The 11th Grinding Conference in China, Huaqiao university, Quanzhou 2001.6(被 EI 光盘版收录)
[35] Zhu Xijing. Research on the New Technology and system of Ultrasonic Honing. The 10th international Manufacturing Conference in China, Xiamen, China, October 2002.
[36] 卢泽生.精密超声振动切削频率对切削力影响规律的研究与仿真. 航空精密制造技术.2006.05
[37] 祝锡晶.功率超声换能器的工程设计原理及方法.山西机械,1999 增刊:4-6
[38] 苏达智.影响珩磨精度的各种要素分析.新技术/新工艺,1989(2)
[39] 祝锡晶.功率超声珩磨缸套加工中谐振系统的试验研究.中国机械工程,2002.09,727-730
[40] 辛志杰.超声珩磨振动系统动态设计.组合机床与自动化加工技术, 2006.06
[41] 李祥林,薛万夫等.振动切削及其在机械加工中的应用.北京:北京科学技术出版社,1985
[42] 张洪丽.超声振动磨削运动学分析.制造技术与机床, 2006.06
[43] Zhao Bo.Surface characteristics in the ultrasonic ductile honing of ZrO2 ceramics using coarse grits. Journal of Materials Processing Technology, Volume 123, Issue 1, 10 April 2002, Pages 54-60
[44] 邝广镛.JHT 系列精密金刚石珩磨头及其应用.机械制造, 1992(9)
[45] Herbst L, et al. Targeting diesel engine efficiency, Industrial Laser Solutions, October 2004
[46] Hargreaves DJ, Scott W. The effect of honing on the frictional resistance of cylinderliners. Society of Manufacturing Engineers, SME paper MR98-215, 1998.
[47] Robota A, Zwein F. Influence of cylinder bore topography on the oil consumption and particulate emissions of a DI TCI diesel engine. MTZ 60 (1999, vol. 4), 1999
[48] Klink U, Flores G. New technologies of honing. Society of Manufacturing Engineers, ASME paper MR98-210, 1998
[49] Sato O, et al. Improvement of piston lubrication in a diesel engine by means of cylinder surface roughness. SAE paper 2004-01-0604
[50] Jocsak J, et al. The effects of cylinder liner finish on piston ring-pack friction. ASME paper ICEF2004-952, 2004
[51]徐可伟.超声振动在精密切削中的应用[J] .新技术·新工艺,2001(3):63-64
[52]陈斌,徐可伟.超声波振动切削薄壁镜筒零件的研究[J] .机械工程师.2001(1):40-42
[53]焦光明,.超声振动切削加工精度的试验研究[J] .电加工,1991(5):15-19
[54]T. Aoyama, I. Inasaki, Development of a Robot System for Metal Molds Polishing, Vol. XXI, Department of Mechanical Engineering, Keio University, Yokohama, 1993, pp. 295–301
[55]J. Brevick, Automated die and mold finishing: an experimental study of short stroke honing, in: Proceedings of the 20th NAMARA International Conference, USA, 1992
[56] B. Nowicki, The new method of free form surface honing, Ann. CIRP 42 (1) (1993)