调Q YAG激光修整青铜CBN砂轮精度及磨削性能研究
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摘要
青铜CBN砂轮具有优良的磨削性能,在精密、超精密磨削,难加工材料成型、高效磨削和磨削自动化中有广泛的应用前景。但由于CBN硬度仅次于金刚石,采用传统的基于力的修整方法修整青铜CBN砂轮很难达到使用要求,严重影响了青铜CBN砂轮优良磨削性能的充分发挥。激光修整技术在修整超硬磨料砂轮方面有其独特的优势,被广泛认为是一种非常有发展前途的方法。
本文通过典型的试验及理论推导,总结出了一种在保证砂轮修整精度和效率的前提下,针对不同砂轮的修整,可有效的缩小激光设备及参数的选择范围的方法。
采用自制200W声光调Q Nd:YAG激光器,并结合机械修整方法,对青铜CBN砂轮进行了复合修整试验研究。经过高功率、大脉冲能量激光粗修,碳化硅滚轮粗修,最后用低功率、小脉冲能量激光精修的方法,将青铜CBN砂轮表面跳动量由400μm修整到28μm。并用体视显微镜对砂轮表面形貌进行了观察,通过铝片刮擦试验和磨削力试验对砂轮的磨削性能进行了研究。结果表明:经上述方法修整过的砂轮,其修整几何精度高、表面形貌良好、磨粒凸出高且分布均匀、磨削性能优良。在修整精度、效率、磨削性能各方面均优于机械法修整的砂轮。
采用自制200W声光调Q Nd:YAG激光器对青铜CBN砂轮进行了变角度入射烧蚀试验,研究了激光入射角度对砂轮修整效率的影响。结果表明:当入射角度为30°到40°时,修整效率最高。
采用自制200W声光调Q Nd:YAG激光器,在入射角为30°的情况下,对青铜CBN砂轮进行了修整试验,并对砂轮表面形貌进行了显微观察。其表面形貌良好,与激光垂直入射修整结果的不同点在于:磨粒背光面存在“山坡”状结合剂突起,并粘附在磨粒表面。经分析,这将增强结合剂对磨粒的把持力,提高砂轮的磨削性能。
With excellent grinding performance, bronze-bonded CBN grinding wheel has a wide application prospect in the field of precision , ultra-precision, high efficiency grinding, grinding automation and difficult processing material forming. Because of the hardness of CBN is only lower than the diamond, the conventional mechanical truing and dressing methods based on force interaction are nearly impossible to meet the requirement for grinding process, which really affects the grinding performance of bronze-bonded CBN grinding wheel. The laser truing and dressing technology has unique advantages for the truing and dressing of super-abrasive wheel, and has been widely recognized that it was a very promising method.
Through typical experiment research and theoretical derivation, a method which can reducing the option range of laser and parameters effectively is obtained for different types wheels, under the premise of guaranteeing the accuracy and efficiency.
The bronze-bonded CBN grinding wheel is trued and dressed with self-made 200W acoustic-optic Q-switched Nd: YAG laser, combining mechanical method. The surface circular run of bronze-bonded CBN grinding wheel reduces from 400μm to 28μm, by the method of truing and dressing in high power and high pulse energy laser, and truing and dressing by silicon carbide wheel secondly, and truing and dressing in low power and low pulse energy laser lastly. The morphology of wheel surface after laser truing and dressing is analyzed by means of stereo microscope. And researches the grinding performance through scratching aluminum and measuring grinding force experiments. The results prove that: after trued and dressed by this method, the surface circular run is low, and the morphology is good. The CBN abrasives have ideal height, good grinding performance and are evenly distributed at the same time. All performance are better compared with the wheels trued and dressed by mechanical method.
The bronze-bonded CBN grinding wheel is ablated in different angles with self-made 200W acoustic-optic Q-switched Nd: YAG laser. And researches the influence of angles for the efficiency of the laser truing and dressing. The results prove that: the efficiency is highest when the angle is between 30 degree and 40 degree.
True and dress bronze-bonded CBN grinding wheel in 30 degree with self-made 200W acoustic-optic Q-switched Nd: YAG laser, and analyze the morphology of wheel surface. The morphology of wheel surface is good. And compared with the wheel trued and dressed by laser in 0 degree the difference is that there is some bond against CBN abrasives looked like hills. That will improve the holding force of CBN abrasives and the grinding performance.
本文通过典型的试验及理论推导,总结出了一种在保证砂轮修整精度和效率的前提下,针对不同砂轮的修整,可有效的缩小激光设备及参数的选择范围的方法。
采用自制200W声光调Q Nd:YAG激光器,并结合机械修整方法,对青铜CBN砂轮进行了复合修整试验研究。经过高功率、大脉冲能量激光粗修,碳化硅滚轮粗修,最后用低功率、小脉冲能量激光精修的方法,将青铜CBN砂轮表面跳动量由400μm修整到28μm。并用体视显微镜对砂轮表面形貌进行了观察,通过铝片刮擦试验和磨削力试验对砂轮的磨削性能进行了研究。结果表明:经上述方法修整过的砂轮,其修整几何精度高、表面形貌良好、磨粒凸出高且分布均匀、磨削性能优良。在修整精度、效率、磨削性能各方面均优于机械法修整的砂轮。
采用自制200W声光调Q Nd:YAG激光器对青铜CBN砂轮进行了变角度入射烧蚀试验,研究了激光入射角度对砂轮修整效率的影响。结果表明:当入射角度为30°到40°时,修整效率最高。
采用自制200W声光调Q Nd:YAG激光器,在入射角为30°的情况下,对青铜CBN砂轮进行了修整试验,并对砂轮表面形貌进行了显微观察。其表面形貌良好,与激光垂直入射修整结果的不同点在于:磨粒背光面存在“山坡”状结合剂突起,并粘附在磨粒表面。经分析,这将增强结合剂对磨粒的把持力,提高砂轮的磨削性能。
With excellent grinding performance, bronze-bonded CBN grinding wheel has a wide application prospect in the field of precision , ultra-precision, high efficiency grinding, grinding automation and difficult processing material forming. Because of the hardness of CBN is only lower than the diamond, the conventional mechanical truing and dressing methods based on force interaction are nearly impossible to meet the requirement for grinding process, which really affects the grinding performance of bronze-bonded CBN grinding wheel. The laser truing and dressing technology has unique advantages for the truing and dressing of super-abrasive wheel, and has been widely recognized that it was a very promising method.
Through typical experiment research and theoretical derivation, a method which can reducing the option range of laser and parameters effectively is obtained for different types wheels, under the premise of guaranteeing the accuracy and efficiency.
The bronze-bonded CBN grinding wheel is trued and dressed with self-made 200W acoustic-optic Q-switched Nd: YAG laser, combining mechanical method. The surface circular run of bronze-bonded CBN grinding wheel reduces from 400μm to 28μm, by the method of truing and dressing in high power and high pulse energy laser, and truing and dressing by silicon carbide wheel secondly, and truing and dressing in low power and low pulse energy laser lastly. The morphology of wheel surface after laser truing and dressing is analyzed by means of stereo microscope. And researches the grinding performance through scratching aluminum and measuring grinding force experiments. The results prove that: after trued and dressed by this method, the surface circular run is low, and the morphology is good. The CBN abrasives have ideal height, good grinding performance and are evenly distributed at the same time. All performance are better compared with the wheels trued and dressed by mechanical method.
The bronze-bonded CBN grinding wheel is ablated in different angles with self-made 200W acoustic-optic Q-switched Nd: YAG laser. And researches the influence of angles for the efficiency of the laser truing and dressing. The results prove that: the efficiency is highest when the angle is between 30 degree and 40 degree.
True and dress bronze-bonded CBN grinding wheel in 30 degree with self-made 200W acoustic-optic Q-switched Nd: YAG laser, and analyze the morphology of wheel surface. The morphology of wheel surface is good. And compared with the wheel trued and dressed by laser in 0 degree the difference is that there is some bond against CBN abrasives looked like hills. That will improve the holding force of CBN abrasives and the grinding performance.
引文
[1]郭志猛,宋月清,陈宏霞等.超硬材料与工具.北京:冶金工业出版社,1996: 48-56
[2]范蜀晋,戴涛.CBN砂轮高速磨削加工的优点与应用.机械学报,1997,24(1): 37-39
[3]周德生.CBN砂轮磨削技术在汽车生产中的应用.金刚石与磨料磨具工程, 1996,92 (2):17-20
[4]周德生.磨削汽车零件的CBN砂轮的研制与应用.汽车技术,1998(6):24-27
[5]蒲前敏,牛海林.磨削汽车零件的CBN砂轮的研制与应用.金刚石与磨料磨具工程,1998,104 (2):12-13
[6]李伯名,赵波等.实用磨削技术.北京:机械工业出版社,1996 :46-48
[7] N.Ramesh Babu,V.Radhakrishman.Investigations on Laser Dressing of Grinding Wheels—PartⅡ,Grinding Perfermance of a Laser Dressed Aluminum Oxide Wheels.Transactions of the ASME,Journal of Engineering for Industry,1989,volⅢ(8):253-261
[8]任敬心,康仁科、史兴宽编著.难加工材料的磨削.北京:国防工业出版社, 1999:24-32
[9]李力钧编著.现代激光加工及其装备.北京:北京理工大学出版社,1993: 73-76
[10] Toshikatsu Nakajima,Kazuhito,Ohashi,Li Xi Sun,et al. Dressing of resinoid bond wheel with moving heat source (1st report)—Transaction of wheel source with a single pulse irradiation of YAG laser.精密工學會志，1993,59(12):1967-1972
[11] N. Ramesh Babu,V. Radhakrishnan,Y. V. G. S. Murti. Investigation on laser dressing of grinding wheels—Part ? : Preliminary study. Journal of Engineering for Industry,Transaction of ASME,1989,111:244-252
[12] N. Ramesh Babu,V. Radhakrishnan. Investigation on laser dressing of grinding wheels—PartⅡ,Grinding performance of a laser dressed Aluminum Oxide wheel. Journal of Engineering for Industry,Transaction of ASME, 1989,111(5):253-261
[13] N. Ramesh Babu,V. Radhakrishnan. Influence of dressing feed on the performance of laser dressed Al2O3 wheel in wet grinding. InternationalJournal of Machine Tools & Manufacture,1995,35(5):661-67169
[14] V. Phanindranath and N. Ramesh Babu. A theoretical model for prediction of groove geometry on laser dressed grinding wheel surface. International Journal of Machine Tools & Manufacture,1996,36(1):1-16
[15] Toshikatsu Nakajima,Kazuhito Ohashi,Li Xi Sun,et al. Dressing of resinoid bond wheel with moving heat source (2st report)—Dressing effect with YAG laser.精密工學會志，1995,61(4):556-560
[16] Toshikatsu Nakajima,Kazuhito Ohashi,Daisuke YAGi. Dressing of resinoid bond wheel with moving heat source (3st report)—Improvement of dressing effect with Q-switched YAG laser.精密工學會志，1997, 63(8):1153-1157
[17] E. Westk?mper,J. Freytag,U. Harbs. Dressing of resin-bonded CBN grinding wheels by means of a pulsed Nd: YAG solid-state laser. In:Proceedings of the LANE’94,1994,22(4):491-500
[18] E. Westk?mper. Grinding assisted by Nd:YAG lasers. Annals of the CIRP, 1995,44(1):317-320
[19] H. -W. Hoffmeister and J.H. Timmer. Laser conditioning of superabrasive grinding wheels. Industrial Diamond Review,2000,24(3):209-218
[20] C.Zhsng,Y.C. Shin. A novel laser assisted truing and dressing techniQue for vitrified CBN wheels. International Journal of Machine Tools & Manufacture,2002,42(2):825-835
[21]陈明,李晓天,孙方宏等.激光在磨削加工中的应用现状分析及试验研究.金刚石与磨料磨具工程,1999,10(6):30-34
[22]陈明,李晓天,孙方宏等.激光技术在砂轮修锐中的应用.制造技术与机床,2000,13(9):23-25
[23]李晓天,陈明,孙方宏等.激光修锐树脂结合剂砂轮的试验研究.航空精密制造技术,1999,33(6):6-8
[24]李晓天,陈明,项玉成等.激光修锐树脂结合剂砂轮的理论计算与试验研究.机械工程师,2000,20(4):43-45
[25]康仁科,原京庭,史兴宽等.超硬磨料砂轮的激光修锐技术研究.中国机械工程,2000,11(5):493-496
[26]康仁科,史兴宽,任敬心等.激光修整金刚石砂轮的研究.西北工业大学学报,1999,17(4):624-628
[27] R.K. Kang,J.T. Yuan,Y.P. Zhang,et al. Truing of diamond wheels by laser.Key Engineering Materials,2001,20(6):137-142
[28]左敦稳,河野良弘,山下俊一等.金刚石砂轮的CO2脉冲激光修锐实验.机械工程学报,1999,35(2):42-45.
[29]李迎,徐鸿钧,邓琦琳.激光修锐树脂结合剂CBN砂轮的研究.航空精密制造技术,1995(3):1-4
[30] F. O. Olsen. Pulsed laser materials processing, ND-YAG versus CO2 lasers. Annals of the CIRP, 1995,42(1):141-145
[31]郭志猛,宋月清,陈宏霞等编著.超硬材料与工具.北京:冶金工业出版社,1996
[32] M. N.奥齐西克著[美],俞昌铭主译.热传导.北京:高等教育出版社, 1983
[33]张洪济.热传导.北京:高等教育出版社,1992
[34] M. Von奥尔曼著,漆海滨,胡洪波,谢柏林等译.激光束与材料相互作用的物理原理及应用.北京:科学出版社,1994
[35] Martin Von Allmen. Laser-beam interactions with materials. Berlin: Spring-Verlag, 1987
[36] Toshikatsu Nakajima,Kazuhito Ohashi,Li Xi Sun et al. Dressing of resinoid bond wheel with moving heat source (2st report)—Dressing effect with YAG laser.精密工學會志,1995,61(4):556-560
[37] Armand Franiz. Advanced thermomechanical rolling technologies for heavy beams. Metallurgical Plant and Technology,1989,(3): 94-108
[38]何晓亮,刘伟,艾毅智.连续固体激光器用声光Q开关.压电与声光, 2002,24(1):23-26
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[43]郑友琴,袁旭军.用CCD实现精密的长度测量.电测与仪器,1998.2,35 (386):45-47
[44]穆向阳,李琳,汤楠.激光位移探测器在三角测量中的应用研究.西安石油大学学报(自热科学版),2004,19(5):39-45
[2]范蜀晋,戴涛.CBN砂轮高速磨削加工的优点与应用.机械学报,1997,24(1): 37-39
[3]周德生.CBN砂轮磨削技术在汽车生产中的应用.金刚石与磨料磨具工程, 1996,92 (2):17-20
[4]周德生.磨削汽车零件的CBN砂轮的研制与应用.汽车技术,1998(6):24-27
[5]蒲前敏,牛海林.磨削汽车零件的CBN砂轮的研制与应用.金刚石与磨料磨具工程,1998,104 (2):12-13
[6]李伯名,赵波等.实用磨削技术.北京:机械工业出版社,1996 :46-48
[7] N.Ramesh Babu,V.Radhakrishman.Investigations on Laser Dressing of Grinding Wheels—PartⅡ,Grinding Perfermance of a Laser Dressed Aluminum Oxide Wheels.Transactions of the ASME,Journal of Engineering for Industry,1989,volⅢ(8):253-261
[8]任敬心,康仁科、史兴宽编著.难加工材料的磨削.北京:国防工业出版社, 1999:24-32
[9]李力钧编著.现代激光加工及其装备.北京:北京理工大学出版社,1993: 73-76
[10] Toshikatsu Nakajima,Kazuhito,Ohashi,Li Xi Sun,et al. Dressing of resinoid bond wheel with moving heat source (1st report)—Transaction of wheel source with a single pulse irradiation of YAG laser.精密工學會志，1993,59(12):1967-1972
[11] N. Ramesh Babu,V. Radhakrishnan,Y. V. G. S. Murti. Investigation on laser dressing of grinding wheels—Part ? : Preliminary study. Journal of Engineering for Industry,Transaction of ASME,1989,111:244-252
[12] N. Ramesh Babu,V. Radhakrishnan. Investigation on laser dressing of grinding wheels—PartⅡ,Grinding performance of a laser dressed Aluminum Oxide wheel. Journal of Engineering for Industry,Transaction of ASME, 1989,111(5):253-261
[13] N. Ramesh Babu,V. Radhakrishnan. Influence of dressing feed on the performance of laser dressed Al2O3 wheel in wet grinding. InternationalJournal of Machine Tools & Manufacture,1995,35(5):661-67169
[14] V. Phanindranath and N. Ramesh Babu. A theoretical model for prediction of groove geometry on laser dressed grinding wheel surface. International Journal of Machine Tools & Manufacture,1996,36(1):1-16
[15] Toshikatsu Nakajima,Kazuhito Ohashi,Li Xi Sun,et al. Dressing of resinoid bond wheel with moving heat source (2st report)—Dressing effect with YAG laser.精密工學會志，1995,61(4):556-560
[16] Toshikatsu Nakajima,Kazuhito Ohashi,Daisuke YAGi. Dressing of resinoid bond wheel with moving heat source (3st report)—Improvement of dressing effect with Q-switched YAG laser.精密工學會志，1997, 63(8):1153-1157
[17] E. Westk?mper,J. Freytag,U. Harbs. Dressing of resin-bonded CBN grinding wheels by means of a pulsed Nd: YAG solid-state laser. In:Proceedings of the LANE’94,1994,22(4):491-500
[18] E. Westk?mper. Grinding assisted by Nd:YAG lasers. Annals of the CIRP, 1995,44(1):317-320
[19] H. -W. Hoffmeister and J.H. Timmer. Laser conditioning of superabrasive grinding wheels. Industrial Diamond Review,2000,24(3):209-218
[20] C.Zhsng,Y.C. Shin. A novel laser assisted truing and dressing techniQue for vitrified CBN wheels. International Journal of Machine Tools & Manufacture,2002,42(2):825-835
[21]陈明,李晓天,孙方宏等.激光在磨削加工中的应用现状分析及试验研究.金刚石与磨料磨具工程,1999,10(6):30-34
[22]陈明,李晓天,孙方宏等.激光技术在砂轮修锐中的应用.制造技术与机床,2000,13(9):23-25
[23]李晓天,陈明,孙方宏等.激光修锐树脂结合剂砂轮的试验研究.航空精密制造技术,1999,33(6):6-8
[24]李晓天,陈明,项玉成等.激光修锐树脂结合剂砂轮的理论计算与试验研究.机械工程师,2000,20(4):43-45
[25]康仁科,原京庭,史兴宽等.超硬磨料砂轮的激光修锐技术研究.中国机械工程,2000,11(5):493-496
[26]康仁科,史兴宽,任敬心等.激光修整金刚石砂轮的研究.西北工业大学学报,1999,17(4):624-628
[27] R.K. Kang,J.T. Yuan,Y.P. Zhang,et al. Truing of diamond wheels by laser.Key Engineering Materials,2001,20(6):137-142
[28]左敦稳,河野良弘,山下俊一等.金刚石砂轮的CO2脉冲激光修锐实验.机械工程学报,1999,35(2):42-45.
[29]李迎,徐鸿钧,邓琦琳.激光修锐树脂结合剂CBN砂轮的研究.航空精密制造技术,1995(3):1-4
[30] F. O. Olsen. Pulsed laser materials processing, ND-YAG versus CO2 lasers. Annals of the CIRP, 1995,42(1):141-145
[31]郭志猛,宋月清,陈宏霞等编著.超硬材料与工具.北京:冶金工业出版社,1996
[32] M. N.奥齐西克著[美],俞昌铭主译.热传导.北京:高等教育出版社, 1983
[33]张洪济.热传导.北京:高等教育出版社,1992
[34] M. Von奥尔曼著,漆海滨,胡洪波,谢柏林等译.激光束与材料相互作用的物理原理及应用.北京:科学出版社,1994
[35] Martin Von Allmen. Laser-beam interactions with materials. Berlin: Spring-Verlag, 1987
[36] Toshikatsu Nakajima,Kazuhito Ohashi,Li Xi Sun et al. Dressing of resinoid bond wheel with moving heat source (2st report)—Dressing effect with YAG laser.精密工學會志,1995,61(4):556-560
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