二维超声振动磨削纳米氧化锆陶瓷的温度场分布特性研究
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摘要
陶瓷材料由于离子键、共价键为主的键性决定其具有高脆、断裂韧性低、弹性模量高等特点,因此硬脆性的陶瓷材料很难进行铣、刨、磨、抛、钻孔等加工。目前,使用金刚石工具(主要是砂轮)的磨削加工是工程陶瓷去除加工的基本途径。由于刀具与工件之间的相对运动速度很快,工件和金刚石的硬度很高,会在刀具与工件界面引起很高的温度,从而导致工件热损伤和加速刀具的磨损。因此,陶瓷材料的广泛应用迫切需要新的高效高质量的先进磨削加工工艺。
将二维超声振动复合加工应用到陶瓷材料的磨削加工中是探寻新的高效磨削技术的创新。本研究通过普通磨削和二维超声振动磨削对比实验,对二维超声振动磨削纳米ZrO_2陶瓷的温度场进行了试验研究。对比磨削比能的特征、形成和分配机理,研究了磨削参数对二维超声振动磨削温度的影响规律,并通过正交试验进行回归分析,给出二维超声振动磨削纳米ZrO_2陶瓷的磨削温度经验公式。在此基础上研究了试件表面形貌、残余应力和显微硬度随磨削温度变化的特征,建立了纳米ZrO_2陶瓷表面变质层结构模型,对它们反映出的材料去除机理和磨削温度的形成机理进行了探讨。并建立了平面磨削时工件的传热学模型,采用有限元法对纳米ZrO_2陶瓷试件在普通和二维超声振动条件下的磨削温度场进行了数值模拟仿真,得到二维超声振动磨削温度场的等温分布图,并获得了磨削温度场的波形组合图。
本论文研究发现采用超声振动磨削技术大大扩大了陶瓷材料磨削的塑性加工区域,有效降低了磨削区的温度,从而有利于纳米陶瓷的磨削。有限元数值模拟仿真结果与试验值基本吻合,从理论上证明了数值模拟仿真结果的可靠性,为研究磨削温度场提供了一种新的方法。
The ceramics material has many merits because of its ionic bond and covalent bond, such as high brittleness, low break toughness, high elastic coefficient and so on, therefore the hard brittle ceramics are very difficult to carry on milling, planning, rubbing, throwing, drilling and so on. At present, the grinding machining using of diamond tool (mainly the grinding wheel) is the essential way of the ceramics removal processing. Because the relative movement speed between the cutting tool and the work piece is very fast, and the hardness of the work piece and the diamond is very high, thus causes the very high temperature in the contact surface between the cutting tool and the work piece, which causes the work piece heat injury and accelerates the cutting tool attrition. So, new advanced grinding methods which have high productivity and high integrality are needed urgently because of the abroad used ceramics.
The application of TDUVG(Two Dimensional Ultrasonic Vibration Grinding) on the grinding machining of ceramics is a creation to search new high-efficient grinding technique. Through common grinding and TDUVG contrast experiments, the nano ceramics grinding temperature fields under TDUVG are experimental studied. Contrasting the characteristics, formation and distribution mechanisms of grinding specific energy, the grinding temperature influence rule was studied from grinding parameters under TDUVG, through the orthogonal regression analysis, the grinding temperature test formula of nano ZrO_2 ceramics can be obtained under TDUVG. On this foundation the effect of grinding temperature on ceramics surface topography , residual stress and microhardness were analyzed, and the grinding surface layer structure model of ceramics is established, the indicated material removal modes and temperature mechanisms are also studied. This paper also established a heat transmission model of ceramics workpiece during surface grinding. Based on the finite element method, the grinding temperature of nano ZrO_2 ceramics under different grinding conditions are numerical simulated .The uniform temperature distribution diagram is obtained and the wave constitution diagram of temperature field is achieved too.
The results of this paper show that the ultrasonic vibration grinding method can greatly enlarge the plastic machining area of engineering ceramics grinding and can effectively lower the temperature in the grinding zone, thereby helps to improve the grinding performance of nano ceramics. The finite element numerical simulation result and the experimental value are basically anastomotic, which theoretically proves the reliability of numerical simulation result and provides a new method for the research of the grinding temperature field.
将二维超声振动复合加工应用到陶瓷材料的磨削加工中是探寻新的高效磨削技术的创新。本研究通过普通磨削和二维超声振动磨削对比实验,对二维超声振动磨削纳米ZrO_2陶瓷的温度场进行了试验研究。对比磨削比能的特征、形成和分配机理,研究了磨削参数对二维超声振动磨削温度的影响规律,并通过正交试验进行回归分析,给出二维超声振动磨削纳米ZrO_2陶瓷的磨削温度经验公式。在此基础上研究了试件表面形貌、残余应力和显微硬度随磨削温度变化的特征,建立了纳米ZrO_2陶瓷表面变质层结构模型,对它们反映出的材料去除机理和磨削温度的形成机理进行了探讨。并建立了平面磨削时工件的传热学模型,采用有限元法对纳米ZrO_2陶瓷试件在普通和二维超声振动条件下的磨削温度场进行了数值模拟仿真,得到二维超声振动磨削温度场的等温分布图,并获得了磨削温度场的波形组合图。
本论文研究发现采用超声振动磨削技术大大扩大了陶瓷材料磨削的塑性加工区域,有效降低了磨削区的温度,从而有利于纳米陶瓷的磨削。有限元数值模拟仿真结果与试验值基本吻合,从理论上证明了数值模拟仿真结果的可靠性,为研究磨削温度场提供了一种新的方法。
The ceramics material has many merits because of its ionic bond and covalent bond, such as high brittleness, low break toughness, high elastic coefficient and so on, therefore the hard brittle ceramics are very difficult to carry on milling, planning, rubbing, throwing, drilling and so on. At present, the grinding machining using of diamond tool (mainly the grinding wheel) is the essential way of the ceramics removal processing. Because the relative movement speed between the cutting tool and the work piece is very fast, and the hardness of the work piece and the diamond is very high, thus causes the very high temperature in the contact surface between the cutting tool and the work piece, which causes the work piece heat injury and accelerates the cutting tool attrition. So, new advanced grinding methods which have high productivity and high integrality are needed urgently because of the abroad used ceramics.
The application of TDUVG(Two Dimensional Ultrasonic Vibration Grinding) on the grinding machining of ceramics is a creation to search new high-efficient grinding technique. Through common grinding and TDUVG contrast experiments, the nano ceramics grinding temperature fields under TDUVG are experimental studied. Contrasting the characteristics, formation and distribution mechanisms of grinding specific energy, the grinding temperature influence rule was studied from grinding parameters under TDUVG, through the orthogonal regression analysis, the grinding temperature test formula of nano ZrO_2 ceramics can be obtained under TDUVG. On this foundation the effect of grinding temperature on ceramics surface topography , residual stress and microhardness were analyzed, and the grinding surface layer structure model of ceramics is established, the indicated material removal modes and temperature mechanisms are also studied. This paper also established a heat transmission model of ceramics workpiece during surface grinding. Based on the finite element method, the grinding temperature of nano ZrO_2 ceramics under different grinding conditions are numerical simulated .The uniform temperature distribution diagram is obtained and the wave constitution diagram of temperature field is achieved too.
The results of this paper show that the ultrasonic vibration grinding method can greatly enlarge the plastic machining area of engineering ceramics grinding and can effectively lower the temperature in the grinding zone, thereby helps to improve the grinding performance of nano ceramics. The finite element numerical simulation result and the experimental value are basically anastomotic, which theoretically proves the reliability of numerical simulation result and provides a new method for the research of the grinding temperature field.
引文
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