外圆磨削磨粒喷射加工机理及表面特性研究
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摘要
传统的外圆磨削中,由于磨削高温使工件表层材料出现缺陷,例如：微裂纹、残余拉应力和表面烧伤等,同时表面的粗糙度和波纹度也较大,这将影响零件的疲劳强度、抗蚀性和接触刚度。因此,重要零件在磨削加工后需要去除表面缺陷层、进行降低粗糙度和波纹度的光整加工。外圆磨削磨粒喷射加工是重要零件在磨削加工后进行去除表面缺陷层、降低粗糙度和波纹度为目的的光整加工新工艺。该工艺是在工件完成磨削后,砂轮停止切入进给,并将磨料混合液注入外圆磨削的楔形接触区。由于砂轮高速旋转,当磨料流体注入砂轮与工件之间的楔形间隙时,就形成了流体动压现象,产生了速度场及压力场。磨料在砂轮约束下获得压力和速度,从而对工件表面进行微去除光整加工实验研究表明,该加工方法既可以保持高的表面形状精度,又可以高效地获得粗糙度Rα。0.19-0.6μm的无缺陷外圆加工表面,实现高效、高精度、低粗糙度,并且可以将磨削和抛光集成的表面精密光整加工。本文以外圆磨削楔形接触区流体场为核心,围绕磨料流体压力场、速度场的建模与仿真和材料去除机理以及工件表面特性等进行了系统的基础性理论和实验研究。本文的主要研究工作包括以下几个方面：
(1)论述了国内外光整加工技术的发展概况,以及光整加工技术的实际应用和最新成就。论述了光整加工技术在机械制造中的重要作用,光整加工技术的分类、特点和发展方向,重点论述了游离磨粒精密光整加工技术的性能特点以及发展方向,阐述了本课题的背景及意义。
(2)依据Navier-Stokes方程和流体流动的连续性方程建立了外圆磨削砂轮与工件之间楔形接触区流体动压力的三维数学模型,结合流体力学和仿真技术,利用Matlab软件,对三维流体压力场进行了计算机模拟和仿真研究。研究了楔形接触区流体动压力的分布规律及其影响因素,其仿真结果与实验结果相接近,为磨削楔形接触区流体压力场的仿真研究提供了方法。
(3)建立了外圆磨削砂轮与工件之间楔形接触区的流体速度场模型,利用Fluent软件,对二维、三维流体速度场进行了计算机模拟和仿真,研究了楔形接触区流体速度场的分布规律及其影响因素。其次研究了单颗、多颗磨粒在楔形接触区的运动轨迹,以及磨粒的释放位置对运动轨迹的影响。最后研究了磨粒在运动过程中随时间的分布规律和磨粒在楔形接触区不同位置的分布情况。
(4)基于磨粒特征尺寸与砂轮和工件之间最小间隙的比值变化,研究了外圆磨削砂轮约束磨粒喷射加工的材料去除机理,即：两体研磨加工和三体冲蚀加工模式的集成。运用概率统计的方法,建立了楔形接触区有效活动磨粒数的数学模型；依据单颗磨粒的材料去除模型和实际参加光整加工的有效磨粒数模型,建立了工件表面材料去除率模型。在外圆磨床上进行了磨粒喷射加工材料去除的实验研究,通过实验结果验证了工件材料去除率的理论模型。
(5)对外圆磨削砂轮约束磨粒喷射加工表面微观形貌进行分析,研究了工件表面的尖峰去除机理和波纹度的均化、改善机理。利用外圆磨床MB1332A对45钢进行磨粒喷射加工实验,用表面轮廓仪对加工前后的工件表面进行微观几何参数测量,并用SEM扫描电镜观察表面微观形貌变化。实验结果表明,随着喷射加工时间的增加,表面微观形貌由方向一致的沟槽过渡到随机的、无方向性的微细凹坑,工件表面网纹交错,表面粗糙度值明显降低。
(6)通过运用自相关函数、功率谱密度函数、互相关函数以及傅立叶谱对磨削加工和磨粒喷射加工外圆表面轮廓进行相关性及谱分析。
(7)对外圆磨削磨粒喷射加工表面进行物理力学性能的评价,研究了光整加工前后工件表面特性对摩擦磨损性能、耐腐蚀性能和金相组织等的影响。并应用分形维数对磨削表面和磨粒喷射加工表面进行辅助性的分析。
(8)通过对平面磨削和外圆磨削砂轮约束磨粒喷射加工楔形接触区压力场、速度场、以及工件表面质量等方面的对比,揭示了光整加工平面工件和外圆工件的差异,讨论了此工艺对加工平面工件的可行性。
(9)总结了论文工作,并提出了探索性的建议。
Because of high grinding temperature, the traditional cylindrical grinding makes defects on the ground surface such as micro-crack、tensile residual stresse、burned layer and so on, and the roughness and ripple values are also greater. All of these would affect the fatigue strength, resistance corroding capability and contact rigidity of the ground surface. Therefore important parts require micro finishing in order to reduce the surface defects and diminish the surface roughness and ripple. A new method named abrasive jet precision machining of cylindrical grinding is to remove surface defect layer and diminish roughness and ripple. When the workpiece was after grinding the slurry of abrasive and liquid solvent was injected to the grinding zone under no depth of cut infeed condition. For the high speed of grinding wheel, when the abrasive slurry is injected to the grinding zone, hydrodynamic pressure has formed, pressure field and velocity field have also formed. The abrasives are driven and energized by the rotating grinding wheel and the surface of workpiece achieved micro removal machining process. The investigate shows that, not only the higher form accuracy of surface but also the no defect cylindrical surface with Ra0.19-0.6μm can be achieved efficiently. Furthermore, cylindrical grinding process and polishing method can be integrated together. This paper has done a lot of systemic research about the model building and simulation on the basic of theory and experiment, which kernel is fluid wedge field of grinding zone、pressure field、velocity field、removal theory and character surface. The purpose of the work is to offer the basis theory and experimental research for the new methord and the primary study work includes these several sides:
(1) Analysis the sketch of the development of the finishing technique, the practical appliance and the newest achievement in and out country. The function, sorts, trait and development of the finishing technology were summarized and the important action of the finishing technique was also discussed. Especially, the loose abrasive finishing technique and the latest achievement of the domestic and international were especially analyzed. The intention and significance of the topic research was also introduced.
(2) Based on Navier-Stokes and continuity equations, the 3D hydrodynamic pressure model of wedge-like zone between the grinding wheel and workpiece was established, combined hydrodynamics and simulation technology,3D hydrodynamic pressure field was simulated by using Matlab, and the distributing principle and affecting factor of the liquid hydrodynamic pressure were investigated. The simulation solution is close to the experiment', which has provide the method for the simulation study of the fluid pressure field of grinding.
(3) The velocity field model of wedge zone between the grinding wheel and cylindrical workpiece was established. The velocity field of liquid in 2D and 3D has been simulated in computer and investigated by using Fluent. The speed distributing principle and influencing factor of liquid velocity field in wedge zone was researched. Secondary the trace of single abrasive、group of abrasive and the effect of trace by different released position were research. Finally the distribution of abrasive by machining time and in different position of wedge were also researched.
(4) Based on the size ratio of characteristic particle size to the thickness between grinding wheel and workpiece, the material removal mechanisms for abrasive jet machining with cylindrical grinding wheel as restraint were investigated. It can be suggested that the material removal mechanisms combined with two-body lapping and three-body erosion. According to the probability statistics method, the number of particles which can remove material actually was established. The model of material removal ratio was established according to the model of material removal by single abrasive and the number of useful abrasive. Experiments were performed on the cylindrical grinder for material removal of abrasive jet machining experiment, and the material removal rate model was found to give a good confirmation of the experimental results.
(5) The microscopic morphology surface of abrasive jet machining process with cylindrical wheel as restrain was analyzed. The peak removal mechanism and homogenizing theory of workpiece surface were investigated. Experiments were performed on cylindrical grinder MB1332A and workpiece material 45. The mocro-parameters and microscopic morphology of workpiece surfaces before and after finishing process were measured respectively. The experimental results showing that the machined surfaces change from continuous and parallel micro-groove and plough to randomly discontinuous micro-pit can be observed with machining time increasing. Furthermore, the new process method can obviously diminish roughness values and cause the surfaces to be smooth.
(6) The outline of the workpiece surface before and after abrasive jet machining process was evaluated by auto correlation function (ACF)、power spectral density (PSD)、cross correlation function (CCF) and Fourier.
(7) The machined surface of abrasive jet machining with cylindrical grinding wheel as restraint was evaluated by physical performance. And the effect of frictional behaviour、wear behaviour、corrosion resistance and metallurgical structure of the workpiece surface were researched before and after abrasive jet machining process. Fractal dimension was used to analyse the workpiece surface as a assistant parameter.
(8) From the contrast of pressure field、velocity field and surface quality between the wedge contact zone of plane grinding and cylindrical grinding, the difference between the plane surface and cylindrical surface was expounded. The method can be used to machine the surface of plane workpiece.
(9) The research work was summarized and exploring suggestion was proposed.
(1)论述了国内外光整加工技术的发展概况,以及光整加工技术的实际应用和最新成就。论述了光整加工技术在机械制造中的重要作用,光整加工技术的分类、特点和发展方向,重点论述了游离磨粒精密光整加工技术的性能特点以及发展方向,阐述了本课题的背景及意义。
(2)依据Navier-Stokes方程和流体流动的连续性方程建立了外圆磨削砂轮与工件之间楔形接触区流体动压力的三维数学模型,结合流体力学和仿真技术,利用Matlab软件,对三维流体压力场进行了计算机模拟和仿真研究。研究了楔形接触区流体动压力的分布规律及其影响因素,其仿真结果与实验结果相接近,为磨削楔形接触区流体压力场的仿真研究提供了方法。
(3)建立了外圆磨削砂轮与工件之间楔形接触区的流体速度场模型,利用Fluent软件,对二维、三维流体速度场进行了计算机模拟和仿真,研究了楔形接触区流体速度场的分布规律及其影响因素。其次研究了单颗、多颗磨粒在楔形接触区的运动轨迹,以及磨粒的释放位置对运动轨迹的影响。最后研究了磨粒在运动过程中随时间的分布规律和磨粒在楔形接触区不同位置的分布情况。
(4)基于磨粒特征尺寸与砂轮和工件之间最小间隙的比值变化,研究了外圆磨削砂轮约束磨粒喷射加工的材料去除机理,即：两体研磨加工和三体冲蚀加工模式的集成。运用概率统计的方法,建立了楔形接触区有效活动磨粒数的数学模型；依据单颗磨粒的材料去除模型和实际参加光整加工的有效磨粒数模型,建立了工件表面材料去除率模型。在外圆磨床上进行了磨粒喷射加工材料去除的实验研究,通过实验结果验证了工件材料去除率的理论模型。
(5)对外圆磨削砂轮约束磨粒喷射加工表面微观形貌进行分析,研究了工件表面的尖峰去除机理和波纹度的均化、改善机理。利用外圆磨床MB1332A对45钢进行磨粒喷射加工实验,用表面轮廓仪对加工前后的工件表面进行微观几何参数测量,并用SEM扫描电镜观察表面微观形貌变化。实验结果表明,随着喷射加工时间的增加,表面微观形貌由方向一致的沟槽过渡到随机的、无方向性的微细凹坑,工件表面网纹交错,表面粗糙度值明显降低。
(6)通过运用自相关函数、功率谱密度函数、互相关函数以及傅立叶谱对磨削加工和磨粒喷射加工外圆表面轮廓进行相关性及谱分析。
(7)对外圆磨削磨粒喷射加工表面进行物理力学性能的评价,研究了光整加工前后工件表面特性对摩擦磨损性能、耐腐蚀性能和金相组织等的影响。并应用分形维数对磨削表面和磨粒喷射加工表面进行辅助性的分析。
(8)通过对平面磨削和外圆磨削砂轮约束磨粒喷射加工楔形接触区压力场、速度场、以及工件表面质量等方面的对比,揭示了光整加工平面工件和外圆工件的差异,讨论了此工艺对加工平面工件的可行性。
(9)总结了论文工作,并提出了探索性的建议。
Because of high grinding temperature, the traditional cylindrical grinding makes defects on the ground surface such as micro-crack、tensile residual stresse、burned layer and so on, and the roughness and ripple values are also greater. All of these would affect the fatigue strength, resistance corroding capability and contact rigidity of the ground surface. Therefore important parts require micro finishing in order to reduce the surface defects and diminish the surface roughness and ripple. A new method named abrasive jet precision machining of cylindrical grinding is to remove surface defect layer and diminish roughness and ripple. When the workpiece was after grinding the slurry of abrasive and liquid solvent was injected to the grinding zone under no depth of cut infeed condition. For the high speed of grinding wheel, when the abrasive slurry is injected to the grinding zone, hydrodynamic pressure has formed, pressure field and velocity field have also formed. The abrasives are driven and energized by the rotating grinding wheel and the surface of workpiece achieved micro removal machining process. The investigate shows that, not only the higher form accuracy of surface but also the no defect cylindrical surface with Ra0.19-0.6μm can be achieved efficiently. Furthermore, cylindrical grinding process and polishing method can be integrated together. This paper has done a lot of systemic research about the model building and simulation on the basic of theory and experiment, which kernel is fluid wedge field of grinding zone、pressure field、velocity field、removal theory and character surface. The purpose of the work is to offer the basis theory and experimental research for the new methord and the primary study work includes these several sides:
(1) Analysis the sketch of the development of the finishing technique, the practical appliance and the newest achievement in and out country. The function, sorts, trait and development of the finishing technology were summarized and the important action of the finishing technique was also discussed. Especially, the loose abrasive finishing technique and the latest achievement of the domestic and international were especially analyzed. The intention and significance of the topic research was also introduced.
(2) Based on Navier-Stokes and continuity equations, the 3D hydrodynamic pressure model of wedge-like zone between the grinding wheel and workpiece was established, combined hydrodynamics and simulation technology,3D hydrodynamic pressure field was simulated by using Matlab, and the distributing principle and affecting factor of the liquid hydrodynamic pressure were investigated. The simulation solution is close to the experiment', which has provide the method for the simulation study of the fluid pressure field of grinding.
(3) The velocity field model of wedge zone between the grinding wheel and cylindrical workpiece was established. The velocity field of liquid in 2D and 3D has been simulated in computer and investigated by using Fluent. The speed distributing principle and influencing factor of liquid velocity field in wedge zone was researched. Secondary the trace of single abrasive、group of abrasive and the effect of trace by different released position were research. Finally the distribution of abrasive by machining time and in different position of wedge were also researched.
(4) Based on the size ratio of characteristic particle size to the thickness between grinding wheel and workpiece, the material removal mechanisms for abrasive jet machining with cylindrical grinding wheel as restraint were investigated. It can be suggested that the material removal mechanisms combined with two-body lapping and three-body erosion. According to the probability statistics method, the number of particles which can remove material actually was established. The model of material removal ratio was established according to the model of material removal by single abrasive and the number of useful abrasive. Experiments were performed on the cylindrical grinder for material removal of abrasive jet machining experiment, and the material removal rate model was found to give a good confirmation of the experimental results.
(5) The microscopic morphology surface of abrasive jet machining process with cylindrical wheel as restrain was analyzed. The peak removal mechanism and homogenizing theory of workpiece surface were investigated. Experiments were performed on cylindrical grinder MB1332A and workpiece material 45. The mocro-parameters and microscopic morphology of workpiece surfaces before and after finishing process were measured respectively. The experimental results showing that the machined surfaces change from continuous and parallel micro-groove and plough to randomly discontinuous micro-pit can be observed with machining time increasing. Furthermore, the new process method can obviously diminish roughness values and cause the surfaces to be smooth.
(6) The outline of the workpiece surface before and after abrasive jet machining process was evaluated by auto correlation function (ACF)、power spectral density (PSD)、cross correlation function (CCF) and Fourier.
(7) The machined surface of abrasive jet machining with cylindrical grinding wheel as restraint was evaluated by physical performance. And the effect of frictional behaviour、wear behaviour、corrosion resistance and metallurgical structure of the workpiece surface were researched before and after abrasive jet machining process. Fractal dimension was used to analyse the workpiece surface as a assistant parameter.
(8) From the contrast of pressure field、velocity field and surface quality between the wedge contact zone of plane grinding and cylindrical grinding, the difference between the plane surface and cylindrical surface was expounded. The method can be used to machine the surface of plane workpiece.
(9) The research work was summarized and exploring suggestion was proposed.
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