喷嘴电解方式ELID磨削的工艺试验及其机理研究
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摘要
在线电解修整(Electrolytic In-Process Dressing, ELID)磨削作为高效的镜面磨削方法被广泛应用于硬、脆等加工材料的镜面磨削。本文研究的喷嘴电解结构的ELID磨削方式即无电极ELID超精密磨削加工方法,以平面为研究对象,进行喷嘴电解方式ELID磨削的新工艺的试验和基础理论研究试验,为将来实现微细零件的加工提供技术基础和理论支持,为进一步扩展该方式的应用范围提供依据。
在进行深入分析和总结喷嘴电解方式ELID磨削原理的基础上,首先对喷嘴电解方式ELID磨削的喷嘴结构、阳极石墨电刷结构等装置进行设计开发,并对现有磨床进行改装,建立满足喷嘴电解方式ELID磨削的试验台,以及ELID专用电源、ELID专用磨削液和金属结合剂金刚石砂轮的选用。同时运用三点平衡法对砂轮进行平衡,选用不同电源参数进行电火花整形的试验研究,得到砂轮的圆度误差在1～2μm以内,满足喷嘴电解方式ELID超精密磨削的要求。
然后在MGK7120×6精密平面磨床上安装喷嘴电解ELID磨削系统对硬质合金材料进行了喷嘴电解方式ELID磨削试验研究。通过改变电解参数,得出磨削力和表面粗糙度的变化规律,选取加工表面质量最优的电解参数；分析了磨削力、比磨削能、表面粗糙度随磨削工艺参数的变化规律。同时,相同的磨削参数下,比较喷嘴电解方式ELID磨削和普通磨削的磨削力、比磨削能和表面粗糙度等试验研究。试验结果表明,喷嘴电解方式ELID磨削能明显改善工件的表面加工质量、降低磨削力,与普通磨削相比较,能更好的实现硬质合金材料的超精密磨削加工
最后,根据脆塑转变理论,提出最大未变形切屑厚度,综合磨削表面形貌分析,结合磨削力、比磨削能和表面粗糙度的变化规律,喷嘴电解方式ELID磨削硬质合金材料主要是以滑擦和耕犁的形式被去除。因此,硬质合金材料去除机理主要为延性去除磨削方式。
As a high efficiency ultra-precision machining technology, Electrolytic In-Process Dressing (ELID) mirror grinding is widely applied in high accuracy machining of hard and brittle materials. In this paper, nozzle-type ELID grinding method was discussed, experiment investigations were conducted, and grinding mechanism was also analyzed. It provided technical foundation and theoretical support for the machining of micro parts in the future, and also provided evidence for the expansion of application scope of ELID grinding.
Firstly, based on analyzing and summarizing the principle of nozzle-type ELID grinding method, the structure of nozzle electrode and the anode brush of ELID system were developed. To establish the experimental table for nozzle-type ELID grinding, the existing grinding machine was improved. The special power supply and grinding fluid of ELID grinding and metal bond diamond wheel were used. Before the experiments, the wheel was balanced by three-point balance method and electro-discharge trued by choosing different power parameters to meet the requirements of nozzle-type ELID grinding. The roundness error of the grinding wheel reached less than 1～2μm.
Then, three kinds of cemented carbides were selected as workpiece materials and the experiments were conducted by using nozzle-type ELID grinding system installed on MGK7120×6 precision surface grinder. By changing the parameters of power supply and grinding process, the variation of the grinding force, specific grinding energy and surface roughness were analyzed and the electrolytic parameters achieving best surface quality were obtained. Meanwhile, under the same grinding parameters, the grinding force, specific grinding energy and surface roughness of nozzle-type ELID grinding and ordinary grinding were compared. The results showed that nozzle-type ELID grinding can significantly improve the surface quality of the workpiece and reduce the grinding force. So, nozzle-type ELID grinding can realize the high quality grinding for cemented carbides.
Finally, according to brittle-ductile transition theory, the maximum undeformed chip thickness of cemented carbides was obtained.. Combined with surface topography of workpiece and the variation rules of grinding force, specific grinding energy and surface roughness, cemented carbides were mainly removed by sliding and plowing in the nozzle-type ELID grinding. Therefore, the removal way of cemented carbides in nozzle-type ELID grinding was mainly ductile removal mode.
在进行深入分析和总结喷嘴电解方式ELID磨削原理的基础上,首先对喷嘴电解方式ELID磨削的喷嘴结构、阳极石墨电刷结构等装置进行设计开发,并对现有磨床进行改装,建立满足喷嘴电解方式ELID磨削的试验台,以及ELID专用电源、ELID专用磨削液和金属结合剂金刚石砂轮的选用。同时运用三点平衡法对砂轮进行平衡,选用不同电源参数进行电火花整形的试验研究,得到砂轮的圆度误差在1～2μm以内,满足喷嘴电解方式ELID超精密磨削的要求。
然后在MGK7120×6精密平面磨床上安装喷嘴电解ELID磨削系统对硬质合金材料进行了喷嘴电解方式ELID磨削试验研究。通过改变电解参数,得出磨削力和表面粗糙度的变化规律,选取加工表面质量最优的电解参数；分析了磨削力、比磨削能、表面粗糙度随磨削工艺参数的变化规律。同时,相同的磨削参数下,比较喷嘴电解方式ELID磨削和普通磨削的磨削力、比磨削能和表面粗糙度等试验研究。试验结果表明,喷嘴电解方式ELID磨削能明显改善工件的表面加工质量、降低磨削力,与普通磨削相比较,能更好的实现硬质合金材料的超精密磨削加工
最后,根据脆塑转变理论,提出最大未变形切屑厚度,综合磨削表面形貌分析,结合磨削力、比磨削能和表面粗糙度的变化规律,喷嘴电解方式ELID磨削硬质合金材料主要是以滑擦和耕犁的形式被去除。因此,硬质合金材料去除机理主要为延性去除磨削方式。
As a high efficiency ultra-precision machining technology, Electrolytic In-Process Dressing (ELID) mirror grinding is widely applied in high accuracy machining of hard and brittle materials. In this paper, nozzle-type ELID grinding method was discussed, experiment investigations were conducted, and grinding mechanism was also analyzed. It provided technical foundation and theoretical support for the machining of micro parts in the future, and also provided evidence for the expansion of application scope of ELID grinding.
Firstly, based on analyzing and summarizing the principle of nozzle-type ELID grinding method, the structure of nozzle electrode and the anode brush of ELID system were developed. To establish the experimental table for nozzle-type ELID grinding, the existing grinding machine was improved. The special power supply and grinding fluid of ELID grinding and metal bond diamond wheel were used. Before the experiments, the wheel was balanced by three-point balance method and electro-discharge trued by choosing different power parameters to meet the requirements of nozzle-type ELID grinding. The roundness error of the grinding wheel reached less than 1～2μm.
Then, three kinds of cemented carbides were selected as workpiece materials and the experiments were conducted by using nozzle-type ELID grinding system installed on MGK7120×6 precision surface grinder. By changing the parameters of power supply and grinding process, the variation of the grinding force, specific grinding energy and surface roughness were analyzed and the electrolytic parameters achieving best surface quality were obtained. Meanwhile, under the same grinding parameters, the grinding force, specific grinding energy and surface roughness of nozzle-type ELID grinding and ordinary grinding were compared. The results showed that nozzle-type ELID grinding can significantly improve the surface quality of the workpiece and reduce the grinding force. So, nozzle-type ELID grinding can realize the high quality grinding for cemented carbides.
Finally, according to brittle-ductile transition theory, the maximum undeformed chip thickness of cemented carbides was obtained.. Combined with surface topography of workpiece and the variation rules of grinding force, specific grinding energy and surface roughness, cemented carbides were mainly removed by sliding and plowing in the nozzle-type ELID grinding. Therefore, the removal way of cemented carbides in nozzle-type ELID grinding was mainly ductile removal mode.
引文
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[2]袁哲俊.精密和超精密加工技术.北京：机械工业出版社,1999
[3]张春河.在线电解休整砂轮镜面磨削理论及应用技术的研究：[博士学位论文].哈尔滨：哈尔滨工业大学,1996
[4]H.Ohmori. Electrolytic In-Process Dressing (ELID) Grinding Method for ultra-Precision Mirror Surface Grinding. Journal of Japan Society for Precision Engineering,1993,59 (9):1451-1455
[5]周曙光,关佳亮,郭东等.ELID镜面磨削技术—综述.制造技术与机床,2001 (2)：38-40
[6]龚庆寿,宁立伟,黄菊生等.ELID精密镜面磨削技术及其应用研究.湖南工程学院学报,2003,13(3)：45-47
[7]T. Nakagawa, Y. Hagiuda, K. Karimori. Cast iron bonded diamond grinding tool and its application to hard materials. Proceedings of the Fifth ICPE, Tokyo, 1984
[8]H.Ohmori,and T.Nakagawa. Analysis of Mirror Surface Generation of Hard and Brittle Materials by ELID Grinding with superfine Grain Metallic Bond Wheels. Annals of the CIRP,1995,44 (1):287-290
[9]H.Ohmori, and T.Nakagawa. Utilization of Nonlinear Condition in Precision Grinding with ELID (Electrolytic In-Process Dressing) for Fabrication of Hard Material Components. Annals of the CIRP,1997,46(1):261-264
[10]T.Suzuki, S.Morita, Lin WeiMin, et al. Ultraprecision ELID grinding for Micro Lens Mold. International Conference on Leading Edge Manufacturing in 21st Century,2005 (1):243-246
[11]T. Saleh, M. Sazedur Rahman, H.S. Lim, et al. Development and performance evaluation of an ultra-precision ELID grinding machine. Journal of Materials Processing Technology,2007,192:287-291
[12]H.Ohmori, Y.Uehara, Weimin Lin. New ELID Grinding Technique for Desk-top Grinding System Based on VCAD Concept. Proceedings of International Conference on Leading Edge Manufacturing in 21st century, 2005,21 (2):703-708
[13]Hitoshi Ohmori, W.Lin, K.Katahirai, et al. Developmental History and Variation of Precision and Efficient Machining assisted with Electrolytic Process Principle and Applications. The First International ELID-Grinding Conference, 2008,6:1-5
[14]Hong Chen, James C. M. Li. Anodic metal matrix removal rate in electrolytic in-process dressing II:Protrusion effect and three-dimensional modeling. Journal of Applied Physics,2000,87 (6):3159-3164
[15]Richard J. Boland. Computer control and process monitoring of electrolytic in-process dressing of metal bond fine diamond wheels for NIF optics. Proceedings of SPIE, Optical Manufacturing and Testing III,1999, 3782:61-69
[16]张春河,袁哲俊,张飞虎等.在线电解修整(ELID)超精密镜面磨削的影响因素初探.金刚石与磨料磨具工程,1996,93(3)：21-23
[17]朱波,袁哲俊,张飞虎等.ELID超精密磨削钢结硬质合金及其表面质量分析.中国机械工程,2000,11(8)：866-868
[18]关佳亮,袁哲俊,张飞虎等.ELID精密镜面磨削用新磨削液的研制.哈尔滨工业大学学报,1998,30(5)：69-71
[19]关佳亮,袁哲俊,张飞虎.ELID精密镜面内孔磨削技术的应用.制造技术与机床,1998(1)：25-26
[20]张飞虎,朱波,栾殿荣等.ELID磨削硬脆材料精密和超精密加工的新技术.宇航材料工艺,1999(1)：51-55
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