摘要
高精度钨钴类硬质合金球主要用于石油钻探抽油泵阀球。硬质合金球和钢球的主要不同是硬度高,与陶瓷球的主要不同是密度大。传统研磨加工生产工艺因受人为因素的影响,一致性和稳定性较差,加工成本高,难以获得高球度的硬质材料球。双自转、三自转研磨方式目前尚停留在实验研究上,在批量生产上的质量控制和设备维护还是难题,而且其设备电气控制系统复杂,制造费用和维护费用比较昂贵。
针对钨钻类硬质合金球的高精度、高效率加工,本文提出了一整套高效精密加工技术方案,采用V型槽冷压孕镶金刚石与平面砂轮行星研磨加工方法进行粗加工,采用三行星盘行星研磨方法进行精加工。通过行星研磨运动原理分析、材料去除过程分析和研磨轨迹仿真证明了该套方案的可行性。
全文围绕行星研磨加工方法的基础理论、关键技术和设备结构改进展开研究,分析了球坯的几何运动,通过无打滑研磨运动分析和坐标变换建立了行星研磨运动的数学模型,运用MATLAB仿真研究了研磨过程中球坯运动轨迹和自转角的变化规律,论证了三行星盘行星研磨加工技术的可行性,建立了行星研磨加工的数学模型,分析了研磨过程中单球球度误差修正过程、批球球径一致化过程。
提出了利用3ML4780立式钢球研磨机改进为三行星盘行星研磨加工装置的设备结构方案,实现了机床粗精加工设备的互换性,为协调生产和节约设备成本创造了有利条件。
分析了行星研磨加工的工艺影响因素,进行了Φ34.925mm的YG13钨钴类硬质合金球的粗磨、精研工艺试验研究,通过正交试验,以直径去除率、平均球度改进量和批直径一致性改进量为指标进行评价,对行星研磨加工的工艺参数进行了优化。
本文关于钨钴类硬质合金球的行星研磨运动原理分析、三行星盘研磨设备及其研磨工艺的研究对于生产高精度硬质合金球具有工程应用价值和工艺理论意义。
High-precision Tungsten-cobalt cemented carbide balls are mainly used by the petroleum drilling pump's valve ball and so on. The cemented carbide balls'main difference from steel balls is their high hardness, however, their main difference from ceramic ball is their high density. By the impact of human factors, the traditional lapping process of the cemented carbide balls got low precision and effieiency, low uniformity and stability, high processing costs. Double(or three) variable rotation lapping methods are still at the experimental research period. There are problems in the manufacture's quality control and the high precision equipment's maintenance. The machine's electrical control system is very complex, and its manufacturing and maintenance costs are very high.
The paper puts forward a set of high-precision machining technology to realize Tungsten-cobalt cemented carbide balls'high-precesion and high-efficiency machining. Uses planetary grinding method, by a cast iron plate with V-groove inlayed diamond and a diamond-resin plate, to do coarse process. Puts forward a new finish machining technology-three-planets planetary lapping method. Demonstrates the feasibility of rough and finish processes by analysising the principle of planetary lapping and the process's material removal, and by simulating the balls' lapping track.
The paper around the planetery grinding method's foundamental theory, key technology and lapping equipments and tools, by analysising the balls'movement on the premise of no slipping and by coordinate transformating, sets up the planetary lapping method's mathematical model, uses MATLAB to simulate the lapping trace and self-rotation angle's changing regulation, demonstrates the three-planets planetary lapping method's technical feasibility, establishes the mathematical model of planetary lapping, analysises the single ball's spherical error correcting process and the batch balls'diameters uniformating process.
The paper puts forward a improved lapping machine's structure, to improve 3ML4780 stand-style steel ball lapping machine to three-planets planetary lapping machine,to realize the interchangeable between coarse machine and finish machine, to create favorable conditions to coordinate manufacture and to reduce machine's innovating cost.
The paper studies the impact facts of planetary lapping process, has done many tests to coarse process and finish process by using YG13-grade 34.925-millimeter diameter cemented carbide balls, optimizes the lapping process's technical parameters by the diameter's reducing rate and the average roundness's modification and the bateh uniformity's modification.
The research, of the principle of tungsten cobalt cemented carbide balls’planetary lappping, of the three-planets planetary lapping equipment, and of the lapping experiment technology, has great value in engineering and has importent process theoretical significance for manufacturing high-precision cemented carbide balls.
引文
[1]吴蒙华,崔云先.抽油泵阀球-阀座密封性能测试装置[J].石油机械.1993,9：55-58
[2]张文华,高兰,朱剑飞.固定阀球密度对抽油泵进油的影响[J].石油钻采工艺.2003,8：33-35;92
[3]陶嶙,陶宪之,杨燕怡,纪士辰.抽油泵阀球失效分析[J].石油机械.1986,11：81-85
[4]王先逵.精密加工技术使用手册[M].机械工业出版社,1999：67-74
[5]聂兰芳,赵学军.钢球加工成圆条件及其影响因素探讨[J].轴承.2001,1：16-18
[6]Rascher. R.研磨钢球的技术现状和发展趋势[J].国外轴承.1992,3：38-42
[7]W.Angele. Finishing high precision quartz balls[J].Precision Engineering. 1980,2(3):119-122
[8]余兴龙,王友冰,索忠壁.四研头超精加工小球机理分析[N].清华大学学报(自然科学报).2003,43：119-122
[9]朱晨.两种钢球研磨方式的力学分析[J].轴承.2000,9：11-13
[10]吴玉厚等.陶瓷球轴承的制造工艺及其相关技术[J].制造技术与机床.1996,11：8-10
[11]Rong-Tsong Lee,Yih-Chyun Hwang,Yuang-Cherng Chiou. Lapping of ultra -precision ball surfaces.Part Ⅰ.Concentric V-groove lapping system [M].International Journal of Machine Tools&Manufacture.2006,46:1146-1156
[12]Rong-Tsong Lee,Yih-Chyun Hwang,Yuang-Cherng Chiou.Lapping of ultra -precision ball surfaces.Part Ⅱ.Eccentric V-groove lapping system[M].International Journal of Machine Tools&Manufacture.2006,46:1157-1169
[13]T.H.C.Childs,H.J.Yoon. Magnetric fluid grinding cell design[N]. Annals of the CIRP.1992,41:343-346
[14]N. Umehara,K.Kato. Fundamental properties of magnetic fluid grinding with a floating polisher[J].Magnetism and Magnetic Materials.1993,122:428-431
[15]K.Kato,B.Zhang,N.Umehara,T.H.C.Childs,D.A.Jones, S.Mahmood. Kinematics of balls in magneticfluid grinding.Trans.JSME,C.1994,572:1433-1439
[16]N.Umehara. Magnetic fluid grinding-a new technique for finishing advanced ceramics[N]. Annals of CIRP.1994,43(1):185-188
[17]N.Umehara, K.Kato,M.Takegoshi. Effects of supporting stiffness of a float and grinding load on fundamental grinding characteristics of ceramic balls in magnetic fluid grinding.Trans. JSME,C.1995,584:1709-1714
[18]T.H.C.Childs,S.Mahmood,H.J.Yoon.The material removal mechanism in magnetic fluid grinding of ceramic ball bearings[J]. Proc.Instn Mech Engrs,Part B.1994,208(1):47-59
[19]R.H.C.Childs,S.Mahmood,H.J.Yoon. The magnetic fluid grinding of ceramic balls[J]. Tribology International.1995,28(6):341-348
[20]N.Umehara, K.Kato, Magnetic fluid grinding of advanced ceramic balls[J].Wear. 1996,200:148-153
[21]T.H.C.Childs,D.A.Jones,S.Mahmood,B.Zhang,K.Kato,N.Umehara. Magnetic fluid grinding mechanics[J].Wear.1994,175:189-198
[22]F.Y.Chang, T.H.C.Childs. Fluid drag, ball interaction and gyroscopic effects in magnetic fluid grinding[M]. Proc.IMechE.2001,215B:1007-1019
[23]Bo.Zhang,Akira Nakajima. Dynamics of magneti fluid support grinding of Si3N4 ceramic balls for ultra-precision bearings and its importance in spherical surface generation[J].Precision Engineering.2003,27:1-8
[24]王军,吴玉厚,等.陶瓷球研磨装置设计和实验[J].机械制造.1997,7：8-12
[25]F.Itoigawa,T.Nakamura,K.Funabashi. Steel ball lapping by lap with V-shape groove.Trans.JSME,59,562(1993):1906-1912
[26]B.Zhang, A.Nakajima. Spherical surface generation mechanism in the grinding of balls for ultraprecision ball bearing[M]. Proc.Instn.Mech Engr.214Part J:351-356
[27]吴玉厚,等.陶瓷球轴承的制造工艺及其相关技术[J].制造技术与机床.1996,11：8-10
[28]王军,吴玉厚,等.精密陶瓷球研磨加工技术研究[J].制造技术与机床.1998,9：34-36
[29]张珂,徐湘辉,吴玉厚,孙红.精密陶瓷球的锥形研磨技术研究[J].金刚石与磨料磨具工程.2005,146(2)：39-42
[30]陆峰,吴玉厚,张珂.混合轴承陶瓷球的锥形研磨加工工艺[N].东北大学学报(自然科学版).2004,25(1)：82-85
[31]李颂华,吴玉厚,等.新型陶瓷球研磨方式的力学分析[N].沈阳建筑工程学院学报(自然科学版).2003,18(3)：229-232
[32]Y.Tani,K.Kawata. Development of high-efficient fine finishing process using magnetic fluid[N].Annals of the CIRP.1984,33:217-220
[33]N.Umehara, K.Kato. A study on magnetic fluid grinding-1st report[J]. Trans. JSME.1988,54:1599-1604
[34]N. Umehara,K.Kato. Principles of magnetic fluid grinding of ceramic balls[J]. Appl. Electromagn. Mater.1990,1:37-43
[35]M.Raghumandan,A.Noori-Khajavi,N.Umehara,R.Komanduri.Magnetic float polishing of advanced ceramics [J].Trans ASME,J.of Manuf.Sci. and Eng.1996,119:521-528
[36]N.Umehara,T.Kirtane,R.Gerlick,V.K.Jain,R.Komanduri. A new apparatus for finishing large size/large batch silicon nitride(Si3N4)balls for hybrid bearing applications by magnetic float polishing(MFP)[J].International Journal of Machine Tools & Manufacture. 2006,46:151-169
[37]Zhang B,Uematsu T，Nakajima A. High efficiency and precision grinding of Si3 N4 ceramic balls aided with magnetic fluid support by using diamond wheels. JSME Int.J.Ser.C.1998,41(3):499-505
[38]F.Y.Chang,T.H.C.Childs.Non-magnetic fluid grinding.wear.1998,223:7-12
[39]T.H.C.Childs,D.J.Moss. Grinding ratio and cost issues in magnetic and non-magnetic fluid grinding.Annals of the CIRP.2000,49(1):255-261
[40]T.H.C.Childs,D.J.Moss. Wear and cost issues in magnetic fluid grinding. Wear.2001,249:509-516
[41]#12
[42]Kurobe.T,Kakuta.H,Onoda.M. Spin angle control lapping of balls(lst report)-theoretical analysis of lapping mechanism[J]. Journal of the Japan Society for Precision Engineering.1996,62(12):1773-1777
[43]Kurobe.T,Kakuta.H,Onoda.M. Spin angle control lapping of balls(2st report)-theoretical analysis of lapping mechanism[J]. Journal of the Japan Society for Precision Engineering.1997,63(5):726-730
[44]Julong Yuan, Binghai Lv,Zhaozhong Zhou,Baochun Tao.Parameters optimization on the lapping process for advanced ceramics by applying taguchi method[J]. Materials Science Forum.2006,532-533:487-491
[45]B.H.Lv,J.L.Yuan,Y.X.Yao,Zhiwei Wang. Research on ultra-precision on lapping technology for KTP[J]. Key Engineering Material,2006,315-316:284-288
[46]J Kang, M Hadfield.The polishing process of advanced ceramicballs using a novel eccentric lapping machine[J].Proc.I Mech E Part B:J.Engineering Manufacture.2005, 219:493-504
[47]J Kang, M Hadfield. A novel eccentric lapping machine for finishing advanced ceramic balls[J].Proc Instn Mech Engrs Part B.2001,215:781-795
[48]J Kang, M Hadfield.The effects of lapping load in finishing advanced ceramic balls on a novel eccentric lapping machine. Proc[J].IMechE.219 Part B:J.Engineering Manufacture. 2005:505-513
[49]Rong-Tsong Lee,Yih-Chyun Hwang,Yuang-Cherng Chiou.Lapping of ultr- precision ball surfaces.Part Ⅱ.Eccentric V-groove lapping system[M].International Journal of Machine Tools&Manufacture.2006,46:1157-1169
[50]任成祖.陶瓷球加工技术及陶瓷球轴承结构设计初探[D].天津大学博士论文.1995：18-19
[51]J.L.Yuan,Z.W.Wang,B.H.Lv.Simulation Study on the Developed Eccentric V-grooves Lapping Mode for Precise Ball[J].Key Engineering Material.2006,304:300-304
[52]王志伟.精密球研磨技术的基础研究[D].浙江工业大学硕士论文,2005：27-35
[53]Ido.M, Hazi.T, Nakazima.M. On the miniature ball bearings- on the effect of revolutional radius in lapping steel balls (in Japanese)[J].Japan Soc.Precision Engng.1960, 26(8):470-475
[54]Ido.M, Nagata.R, Hazi. T. On the miniature ball bearings-on the effect of lap groove angle in lapping steel balls(in Japanese) [J]. Japan Soc. Precision Engng.1962,28(6):317-323
[55]Ido.M, Hazi.T. On the miniature ball bearings-on the lapping pressure in lapping steel ball (Partl)(in Japanese)[J].Japan Soc. Precision Engng.1958,24(4):161-168
[56]Ido.M, Hazi.T, Nakazima.M. On the miniature ball bearings-on the effect of lapping liquid in lapping steel balls(in Japanese)[J]. Japan Soc.precision Engng.1961,27(5):261-267
[57]Ido.M, Hazi.T. On the miniature ball bearings-on the lapping pressure in lapping steel ball(Part2)(in Japanese)[J].Japan Soc.Precision Engng.1958,24(5):161-168
[58]孙永安,李县辉.国外陶瓷球加工技术及其应用[N].陶瓷学报.2002,23(2)：145-148
[59]黄传真,艾兴,等.新型陶瓷轴承研究的现状与展望[J].中国陶瓷工业.1999,6(2)：25-27
[60]Wu YH,Zhang K,Sun H. Rubbing process technology of HIPSN ceramic balls[J].Key Engineering Materials.2001,202-203:185-188
[61]蒋沂萍.混合轴承及陶瓷球研制近况[J].轴承.2001,2：33-35
[62]王国栋.硬质合金生产原理[M].北京.冶金工业出版社,1998：110-130
[63]何改云,宋占杰.球度误差评定方法的研究[J].计量技术,1999,3：16-19
[64]朱训生,任新生,薛秉源.球度最小二乘评定的一般公式[J].上海交通大学学报,1998,9：45-46
[65]朱训生,任新生.实用球度测量的经圆法及其实验[J].计量技术.1999,3：12-15
[66]唐红霞.钢球表面粗糙度测量方法探讨[J].轴承,1 999,11：22-26
[67]张泰昌.表面缺陷的检测与评定[J].制造技术与机床,2000,4：24-27
[68]Aichard.J.F. Mechanical polishing of metals-scientific argument of long standing[J]. Phy,Bull.1985,36:212-214
[69]理查德.J,布鲁克.陶瓷工艺[M].清华大学新型陶瓷精细工艺国家重点实验室译.科学出版社,1999：23-31
[70]黄晨.行星式精密球体高效研磨加工机理与工艺研究[D].浙江工业大学硕士论文,2008：31-40
[71]朱晨.钢球研磨迹线理论与钢球表面两类研磨迹线分析[N].湘潭大学自然科学学报,1996(1)：42-46