摘要
磁力研磨是一种先进的研磨加工技术,具有切深小、柔性适应强等优点,但同时也有加工效率低、磨料寿命短且制造工艺复杂等缺点。电化学加工是一种基于阳极电化学溶解的加工方式,从理论上讲,是一种属于离子级去除的加工方式,适合于任何金属及合金材料的加工。但是,由于加工过程中,涉及的因素过多,如电解液的流场、极间电场、温度场等对加工都有影响,要达到良好的加工效率和表面质量对工艺过程控制以及装备要求高。
本文以钝化膜为结合点将电化学与磁力研磨复合,主要从复合工具及装置研制、工艺实验、复合机理三个方面进行研究。复合工具的结构形式直接决定复合工艺以何种形式实现,本文针对电化学与磁力研磨的不同工艺特点,提出了中空电磁极相间复合工具。对于中空电磁极相间的结构而言,最为关键的是电解液是否能够有效到达电化学工作区域。对此,本文使用有限元方法建立了中空工具工作间隙的磁场模型,并在计算所得磁场分布的基础上推测了磨料刷与通液空腔的形貌。为了使磁路结构能够更加方便的适用于平面类零件的加工工艺,本文在分析了闭合与开放两种磁路结构的基础上提出了主线圈加辅助线圈的磁路结构,有限元与实测结果都证明辅助线圈能够有效增强加工间隙内的磁场强度。
与传统磁力研磨不同,本文所采用的工具结构和铁磁性磨料都具有特殊性,所以对复合工具下的磁力研磨状态进行了研究。首先,分析了铁磁性磨料在磁场下的力学行为。结合单颗磨料在磁场中受力的数学模型与有限元分析的结果,对研磨压力进行了数值模拟,得到了单颗磨料在工具径向上的研磨压力分布。设计实验装置测得了粉末松散状态下的Fe3O4相对磁导率,并依据这个数值对磨料刷的相对磁导率进行了计算。根据相对磁导率以及磨料与研磨压力的分布,对整体研磨压力进行了估算,计算值与文献测量值相近。其次,进行了不同加工时间、转速、振动频率磁极电流、加工间隙的纯磁力研磨参数工艺实验。此外,使用高速摄像仪观测了不同转速下的磨料刷形貌,分析了不同转速下磨料刷形貌与磨料残余的原因,并且建立了理论最高转速模型,结合磁场有限分析的结果对最高转速进行了估算。
磁力研磨与电化学的复合并不是简单工艺叠加,而存在一些交互影响。磁场对电化学过程可能会产生影响,而电解液液流对磨料残余、磨料刷形貌也可能产生影响。本文在流场分析的基础上,讨论了流场与磨料残余、磨料刷形貌之间关系。通过理论分析与实验现象发现：在存在电解液液流的情况下,即使达到紊流的流量,磨料残余依然存在但数量减少,而磨料刷也不会被冲溃。与此同时,本文也评估了这些绝缘残余磨料对电化学溶解精度的影响并且发现这种影响非常小。对磁场条件下的电化学行为,本文建立了叠加磁场情况下的离子轨迹模型,分析了在电场平行向叠加磁场对离子轨迹的影响,并测量了不同材料不同电解液在叠加磁场情况下的阳极极化曲线。
在本文第六章中,课题对基于中空电磁极相间复合工具的电化学磁力研磨复合加工进行了系统的工艺实验研究。通过更改电化学与磁力研磨的相关工艺参数,得到不同复合状态的工艺效果。通过实验发现,磁力研磨与电化学的匹配关系对复合加工的表面质量和加工效率影响很大。要达到良好的复合效果,必须使得电化学加工不进入到超钝化溶解阶段。在这个前提下,除膜速度越快表面质量越好。在适当工艺条件下,使用复合工艺加工A3钢和Al6061表面粗糙度Ra可达到0.2pm以下,而同样条件下的磁力研磨仅为0.4～0.6μm。
为了揭示电化学磁力研磨的复合机理,本文首先分别建立了磁力研磨、电化学加工的加工模型。其中,根据实验现象,在磁力研磨模型中引入了磨料损耗函数,比较好的吻合了实验结果。然后,本文根据工艺实验的相关结论与实验现象,提出了电化学磁力研磨复合加工的建模思想,对复合加工过程进行了仿真,从一定程度上解释了电化学与磁力研磨的复合机理。
As an advanced polishing technology, magnetic abrasive finishing (MAF) is flexible, adaptable and with low mechanical damage, but it also has disadvantages of low process efficiency, short service life and complex manufacturing procedure of abrasives. Electrochemical machining (ECM) bases on anodic dissolution,which is suitable for all metal and alloy precision process in theory. But actuality, there are too many parameters which will effect the ECM process such as fluent, heat, electric etc. It requires good quality equipment and strict control of technical process for better process efficincy and surface qulity.
This paper presents a hybrid process of ECM and MAF based on the passivation film. It mainly mainly studies the following three aspects of machine tool designing, machining experiments and hybrid principles. The structure form of the composited tool decided the form of the hybrid process. It proposed a hollow structure with electrodes separated by magnetic pole based on the properties of ECM and MAF respectively. For this structure, the most important part is to make sure the electrolyte can reach the ECM working area. Therefore, a FEM model of the MAF working gap has been analysed to conjecture the shape of the abrasive brush in the paper. From the observations and measurements, the FEM results have found to be credible. To make the magnetic circuit adaptable to the plane parts, it presents a magnetic circuit compounded by a primary and auxiliary coil based on the analysis of the open and closed magnetic circuits. The auxiliary coil has been proved to enhance the magnetic field in the working gap by the measured and FEM results.
Different from traditional MAF process, this paper applied different tool structure and abrasives. Firstly, in order to investigate the status of MAF under the composited tool, the force analysis of the magnetic abrasive has been carried out. Integrated the FEM results and mathematics model, machining force distribution has been calculated. A device to test magnetic permeability of ferramic has been designed. With the magnetic permeability from measurement, the machining pressure mathematical model on the whole working area has been built. Secondly, to study the statue of MAF under the composited tools, the experiments about the parameters of MAF process, such as machining time, rotating speed, vibration frequency, exciting current, and working gap size have been carried out. Thirdly, high rate photographic instrument is applied to observe the abrasive brush shape under different rotating speed. The highest rotating model also has been built and calculated.
The hybrid process of EMAF is not simply overlying of MAF and ECM process but has interacive infulunce on each other. The connection between fluent and residual abrasives has been discussed in the paper. As a result, it find there is residual abrasive even under turbulence condition but not that many as in the MAF process. Meanwhile, the effects of these residual abrasives to ECM process has also been estimated which is found to be little. A model of the magnetic field influence on the ion tracks has been built. We tests polarization curves of workpiece materials with different electrolyte solutions and magnetic field conditions.
The sixth chapter of this paper is mainly about the parameters experiments of the EMAF process. By adjusting the parameters of MAF and ECM respectively, it can alter the relative strength between ECM and MAF in the compound process of EMAF. The matching relations bewteen the ECM and MAF process is necessary to achieve good surface quality and efficiency for the hybrid process of EMAF. To reach good combination effect, the state of the ECM process must be under passivation. The MAF process is a key factor to keep ECM under that state. Under properly conditions, the surface roughness Ra can reach below0.2μm while it is in range from0.4to0.5μm in the MAF process with same conditions.
To reveal the principle of the hybrid process of EMAF, this paper builds theory models of ECM and MAF respectively. Accoding to the phenomenas of experiments, it intruduces in the loss factor of the abrasive which fitted experiments well. On account of the phenomenas and conclusions of the experiments, it proposes a theory that the thinkness of the passivation film decided the current distribution of ECM. Base on that theory, the ECM and MAF models are finally iterated as the EMAF model, which model partly explained the hybrid theory.
引文
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