复杂螺旋面钻尖刃磨原理及刃磨技术的研究
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摘要
钻削在金属切削中应用很广,孔加工是最常用的材料切除方法之一。根据行业不同,其工序量达总加工工序量的20%-40%,所以,钻削加工技术一直是机械加工领域倍受人们研究的重要课题。
常用的钻头是锥面麻花钻,但这种钻尖后刀面的加工机床刃磨运动关系较复杂,不便于准确控制钻尖的几何参数。本课题研究复杂螺旋面钻尖刃磨原理及刃磨技术,这种钻头刃磨时的运动关系简单,能够精确地控制刃磨参数。论文着重在以下几方面进行研究：
(1)钻头及其刃磨技术的发展历程。评述几种常用钻尖后刀面的刃磨方法,提出研究螺旋面钻头的必要性和可行性研究。
(2)钻尖是钻头承担切削的最重要部分,对钻头的研究主要是对钻尖的研究。针对常用钻头所存在的问题,从钻尖刃磨原理及其运动关系的分析入手,建立了钻头后刀面及前刀面的数学模型。
(3)分析刃磨参数与钻头的几何参数的关系。
(4)对复杂螺旋面钻尖的几何参数进行了分析,建立了一系列的几何参数的数学模型,从理论上分析了螺旋面钻尖的几何角度分布的合理性,这有助于对钻尖的参数进行分析和精确的控制。
(5)实验分析。把根据本课题原理刃磨出的复杂螺旋面钻尖与其他钻尖一并应用到钻削实验中,通过改变刃磨参数,进行对比实验,同时对不同钻尖的钻削力及钻削质量进行分析。
实验表明：复杂螺旋面钻尖与普通麻花钻钻尖相比,复杂螺旋面钻尖在靠近钻心处有较大的后角,并使横刃为“S”形,因此定心好,切入稳定,钻削轴向力小,具有比较好的排屑能力,并且所钻孔径与钻头的直径很接近,钻孔质量较好。
Drilling is greatly applied in metal cutting. The hole-machining is one of the most methods for material machining. Drilling sequence amount achieves 20-40% of total machining sequences. Therefore, drilling technology is important research project in machining area.
Nowadays, the usual drill is the conical drill. But the grinding motions of the machine tools are very complex for the conical drill and can't exactly control geometric parameters of the drill points. This thesis is to study helical drill, which the motions of grinding are simple; the grinding parameters can be exactly control. The thesis study on the following area:
Firstly, developing history of drill and grinding technology are reviewed. Grinding methods of flank surfaces of several usual drill points are discussed. The necessity and feasibility for researching complex helical drill are proposed.
Secondly, drill point is the most important part of a drill for drilling. To research of drill is mainly to research of drill point. According to the defects of common drill points, analyzing of grind principle and its motion relation, a new kind of drill, which is called as complex helical point drill is established. The mathematical models of helical point are established.
Thirdly, the relation of the grinding parameters and geometric parameters is analyzed.
Fourthly, analyzing geometric parameters of complex helical drill point and developing their mathematic models, achieving distribution reasonability of geometric angles of the helical drill, it is helpful to analyze and exactly control the parameters of drill point.
Fifthly, experiment analyzes. Complex helical drill point and common drill points are used in the drilling experiment, changing their grinding parameters in the contrastive experiment. We will analyze different drill points on the drilling force and drilling quality.
It is clear that complex helical drill point has an "S" contour with a radiuses crown chisel, which reduces the thrust force and makes the drills self-centering. The S-shape chisel edge has a lower negative rake angle than a conventional chisel edge.
常用的钻头是锥面麻花钻,但这种钻尖后刀面的加工机床刃磨运动关系较复杂,不便于准确控制钻尖的几何参数。本课题研究复杂螺旋面钻尖刃磨原理及刃磨技术,这种钻头刃磨时的运动关系简单,能够精确地控制刃磨参数。论文着重在以下几方面进行研究：
(1)钻头及其刃磨技术的发展历程。评述几种常用钻尖后刀面的刃磨方法,提出研究螺旋面钻头的必要性和可行性研究。
(2)钻尖是钻头承担切削的最重要部分,对钻头的研究主要是对钻尖的研究。针对常用钻头所存在的问题,从钻尖刃磨原理及其运动关系的分析入手,建立了钻头后刀面及前刀面的数学模型。
(3)分析刃磨参数与钻头的几何参数的关系。
(4)对复杂螺旋面钻尖的几何参数进行了分析,建立了一系列的几何参数的数学模型,从理论上分析了螺旋面钻尖的几何角度分布的合理性,这有助于对钻尖的参数进行分析和精确的控制。
(5)实验分析。把根据本课题原理刃磨出的复杂螺旋面钻尖与其他钻尖一并应用到钻削实验中,通过改变刃磨参数,进行对比实验,同时对不同钻尖的钻削力及钻削质量进行分析。
实验表明：复杂螺旋面钻尖与普通麻花钻钻尖相比,复杂螺旋面钻尖在靠近钻心处有较大的后角,并使横刃为“S”形,因此定心好,切入稳定,钻削轴向力小,具有比较好的排屑能力,并且所钻孔径与钻头的直径很接近,钻孔质量较好。
Drilling is greatly applied in metal cutting. The hole-machining is one of the most methods for material machining. Drilling sequence amount achieves 20-40% of total machining sequences. Therefore, drilling technology is important research project in machining area.
Nowadays, the usual drill is the conical drill. But the grinding motions of the machine tools are very complex for the conical drill and can't exactly control geometric parameters of the drill points. This thesis is to study helical drill, which the motions of grinding are simple; the grinding parameters can be exactly control. The thesis study on the following area:
Firstly, developing history of drill and grinding technology are reviewed. Grinding methods of flank surfaces of several usual drill points are discussed. The necessity and feasibility for researching complex helical drill are proposed.
Secondly, drill point is the most important part of a drill for drilling. To research of drill is mainly to research of drill point. According to the defects of common drill points, analyzing of grind principle and its motion relation, a new kind of drill, which is called as complex helical point drill is established. The mathematical models of helical point are established.
Thirdly, the relation of the grinding parameters and geometric parameters is analyzed.
Fourthly, analyzing geometric parameters of complex helical drill point and developing their mathematic models, achieving distribution reasonability of geometric angles of the helical drill, it is helpful to analyze and exactly control the parameters of drill point.
Fifthly, experiment analyzes. Complex helical drill point and common drill points are used in the drilling experiment, changing their grinding parameters in the contrastive experiment. We will analyze different drill points on the drilling force and drilling quality.
It is clear that complex helical drill point has an "S" contour with a radiuses crown chisel, which reduces the thrust force and makes the drills self-centering. The S-shape chisel edge has a lower negative rake angle than a conventional chisel edge.
引文
1.王勇.麻花钻钻尖的重刃磨技术及计算机仿真[D],武汉理工大学,2002
2.陈桂平.新型硬质合金群钻的数学模型与刃磨实验研究[D],湖南大学,2003
3.罗霞玉.新型钻头的几何特性分析及实验研究[D],湖南大学,2001
4.周志雄.一种新型钻头及其刃磨技术的研究[D],湖南大学,2001
5. 吕彦明,陈五一,陈鼎昌.复杂螺旋面钻尖刃磨原理及实现[J],中国机械工程,2003
6. H. Hocheng,C.C.Tsao. Effects of special drill bits on drilling-induced delamination of composite materials [J], International Journal of Machine Tools & Manufacture, 2006,46:1403-1416.
7. A.Velayudham, R.Krishnamurthy. Effect of point geometry and their influence on thrust and delamination in drilling of polymeric composites [J], Journal of Materials Processing Technology,2006
8. C.C.Tsao, H.Hocheng. Effects of exit back-up on delamination in drilling composite materials using a saw drill and a core drill
9. H. Hocheng, C.C.Tsao. The path towards delamination-free drilling of composite materials[J], Journal of Materials Processing Technology,2005,167:251-264.
10. H. Hocheng, C.C.Tsao. Effect of eccentricity of twist drill and candle stick drill on delamination in drilling composite materials[J], International Journal of Machine Tools & Manufacture,2005,45:125-130.
11. C.C.Tsao, H. Hocheng. Taguchi analysis of delamination associated with various drill bits in drilling of composite material[J], International Journal of Machine Tools & Manufacture,2004,44:1085-1090.
12. H. Hocheng, C.C.Tsao. Comprehensive analysis of delamination in drilling of composite materials with various drill bits[J], Journal of Materials Processing Technology,2003,140:335-339.
13. C.C.Tsao, Hocheng. The effect of chisel length and associated pilot hole on delamination when drilling composite materials[J], International Journal of Machine Tools & Manufacture,2003,43:1087-1092.
14. M. Pirtini, I. Lazoglu. Forces and hole quality in drilling[J], International Journal of Machine Tools & Manufacture,2005,45:1271-1281.
15. Sedat Karabay. Analysis of drill dynamometer with octagonal ring type transducers for monitoring of cutting forces in drilling and allied process[J], Materials and Design,2005
16.曹正铨.钻尖的数学模型与钻削实验研究[M],北京：北京理工大学出版社,1992
17.北京永定机械厂群钻研究小组.群钻[M],上海：上海科学技术出版社,1982
18.李粤军,曹正铨,林丞.曲线刃锥面钻尖的数学模型及其计算机辅助设计[J],中国高校金属切削研究会第三届全国年会科研论文,1987
19.林丞,曹正铨.群钻数学模型及其刃磨参数计算[J],工具技术,1990
20. S.K.Kang, K.F.Ehmann and C.Lin. A CAD APPROACH TO HELICAL Groove Machining[J], Mathematical Model and Model Solution, Int, J.Mach. Tools Manufact,1996, Vol.36:141-153.
21.乐兑谦.金属切削刀具[M],北京：机械工业出版社,1984
22. J.Agullo-Batlle, S.Cardona-foix, C.Vinas-sanz. On the Design of Milling Cutters or Grinding Wheels for Twist Drill Manufacture[J], A CAD Approach, Proc of the 25th Int. MTDR Conference,1985
23. K.F.Ehmann. Grinding Wheel Profile Definition for the Manufacture of Drill Flute [J], Annals of the CIRP,1990,39(1).
24. D.W.Dudley. H.Poritsky. On Cutting and Hobbing Gears and Worms[J], J. of Applied Mechanics,1943
25. S.Kaldor, A. M. Rafael, D.Messinger. On the CAD of Profiles for Cutters and Helical Flutes-Geometrical Aspects[J], Annals of the CIRP,1988,37(1).
26. M.Y. Friedman, M. Bolselavski, I. Meister. The Profile of a Helical Slot Machined by a Disk-Type Cutter with an Infinitesimal Width, Considering Undercutting [J], Proc. Of the 13td International Machine Tool Design and Research Conference, 1972
27. D.S.Sheth, S.Malkin. CADICAM for Geometry and Process Analysis of Helical Groove Machining [J], Annals of the CIRP,1990, Vol.39(1).
28. S.K.Kang, C. Lin, and K. F. Ehmann:Comparative Analysis of Planar and Helical Micro Drill Points[J], Transaction of NAMRI/SME,1993, Vol ⅩⅪ:189-196.
29. Wei Zhang, Fengbao He,Dilin Xiong. Parameterized Geometric Design for Complex Helical Drill Point[J], Journal of Manufacturing Science and Engineering, 2005, Vol.127:319-327.
2.陈桂平.新型硬质合金群钻的数学模型与刃磨实验研究[D],湖南大学,2003
3.罗霞玉.新型钻头的几何特性分析及实验研究[D],湖南大学,2001
4.周志雄.一种新型钻头及其刃磨技术的研究[D],湖南大学,2001
5. 吕彦明,陈五一,陈鼎昌.复杂螺旋面钻尖刃磨原理及实现[J],中国机械工程,2003
6. H. Hocheng,C.C.Tsao. Effects of special drill bits on drilling-induced delamination of composite materials [J], International Journal of Machine Tools & Manufacture, 2006,46:1403-1416.
7. A.Velayudham, R.Krishnamurthy. Effect of point geometry and their influence on thrust and delamination in drilling of polymeric composites [J], Journal of Materials Processing Technology,2006
8. C.C.Tsao, H.Hocheng. Effects of exit back-up on delamination in drilling composite materials using a saw drill and a core drill
9. H. Hocheng, C.C.Tsao. The path towards delamination-free drilling of composite materials[J], Journal of Materials Processing Technology,2005,167:251-264.
10. H. Hocheng, C.C.Tsao. Effect of eccentricity of twist drill and candle stick drill on delamination in drilling composite materials[J], International Journal of Machine Tools & Manufacture,2005,45:125-130.
11. C.C.Tsao, H. Hocheng. Taguchi analysis of delamination associated with various drill bits in drilling of composite material[J], International Journal of Machine Tools & Manufacture,2004,44:1085-1090.
12. H. Hocheng, C.C.Tsao. Comprehensive analysis of delamination in drilling of composite materials with various drill bits[J], Journal of Materials Processing Technology,2003,140:335-339.
13. C.C.Tsao, Hocheng. The effect of chisel length and associated pilot hole on delamination when drilling composite materials[J], International Journal of Machine Tools & Manufacture,2003,43:1087-1092.
14. M. Pirtini, I. Lazoglu. Forces and hole quality in drilling[J], International Journal of Machine Tools & Manufacture,2005,45:1271-1281.
15. Sedat Karabay. Analysis of drill dynamometer with octagonal ring type transducers for monitoring of cutting forces in drilling and allied process[J], Materials and Design,2005
16.曹正铨.钻尖的数学模型与钻削实验研究[M],北京：北京理工大学出版社,1992
17.北京永定机械厂群钻研究小组.群钻[M],上海：上海科学技术出版社,1982
18.李粤军,曹正铨,林丞.曲线刃锥面钻尖的数学模型及其计算机辅助设计[J],中国高校金属切削研究会第三届全国年会科研论文,1987
19.林丞,曹正铨.群钻数学模型及其刃磨参数计算[J],工具技术,1990
20. S.K.Kang, K.F.Ehmann and C.Lin. A CAD APPROACH TO HELICAL Groove Machining[J], Mathematical Model and Model Solution, Int, J.Mach. Tools Manufact,1996, Vol.36:141-153.
21.乐兑谦.金属切削刀具[M],北京：机械工业出版社,1984
22. J.Agullo-Batlle, S.Cardona-foix, C.Vinas-sanz. On the Design of Milling Cutters or Grinding Wheels for Twist Drill Manufacture[J], A CAD Approach, Proc of the 25th Int. MTDR Conference,1985
23. K.F.Ehmann. Grinding Wheel Profile Definition for the Manufacture of Drill Flute [J], Annals of the CIRP,1990,39(1).
24. D.W.Dudley. H.Poritsky. On Cutting and Hobbing Gears and Worms[J], J. of Applied Mechanics,1943
25. S.Kaldor, A. M. Rafael, D.Messinger. On the CAD of Profiles for Cutters and Helical Flutes-Geometrical Aspects[J], Annals of the CIRP,1988,37(1).
26. M.Y. Friedman, M. Bolselavski, I. Meister. The Profile of a Helical Slot Machined by a Disk-Type Cutter with an Infinitesimal Width, Considering Undercutting [J], Proc. Of the 13td International Machine Tool Design and Research Conference, 1972
27. D.S.Sheth, S.Malkin. CADICAM for Geometry and Process Analysis of Helical Groove Machining [J], Annals of the CIRP,1990, Vol.39(1).
28. S.K.Kang, C. Lin, and K. F. Ehmann:Comparative Analysis of Planar and Helical Micro Drill Points[J], Transaction of NAMRI/SME,1993, Vol ⅩⅪ:189-196.
29. Wei Zhang, Fengbao He,Dilin Xiong. Parameterized Geometric Design for Complex Helical Drill Point[J], Journal of Manufacturing Science and Engineering, 2005, Vol.127:319-327.