磨粒流精密光整加工的微切削机理
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摘要
利用磨粒流的流变特性,通过对应力张量的分析,研究了磨粒流加工中的微切削力。提出了磨粒流加工是兼挤压与微去除方式为一体的复合加工,微切削动力主要来自于磨粒挤压力、磨粒的犁削力及磨料介质的剪切力。建立了磨粒流动力学模型,通过改变磨粒流流道的加工条件和测试加工过程的接触区压力、去除量及表面粗糙度等参数,用量化的方式揭示了磨粒流加工中抽象微切削力的变化规律。最后,结合COMSOL Multiphysics软件的CFD模块数值仿真了剪切力。结果显示:基于加模芯的方法有效地提高了磨粒流加工的微切削力,滑块4经15次循环后表面粗糙度由加工前的2.918μm下降为1.027μm,而去除量下降了0.09g。实验表明,磨粒流加工中去除量确有变化,但随着加工次数增加去除作用迅速削弱,而表面粗糙度在挤压力的作用下仍有所降低。
On the basis of rheological behaviors of abrasive flow,the stress tensor was analyzed to explore the micro-cutting force of the Abrasive Flow Machining(AFW)process.It points out that the abrasive flow precision machining is a combined machining method made by extrusion and micro removal,and the micro-cutting force of the AFW is come from a combination of medium share force,squeezing force and plowing force.The dynamics model was established and general change law of the micro-cutting force in AFW processing were revealed quantitatively by changing processing conditions and processing parameters,such as the pressure of contact region,removal amounts and surface roughness.Finally,the shear force was simulated numerically by using the CFD module of COMSOL multiphysics software.The experiment results show that the mold core is conductive to increasing the micro-cutting force,the surface roughness Raof the solider(number four)has decreased from 2.918μm to 1.027μm and the removal is 0.09 g after 15 processing cycles.The results demonstrate that the removal is changed in the abrasive flow machining process,however,the removal action is quickweakened with the increase of the times of extrusion and the surface roughness is still improved.
On the basis of rheological behaviors of abrasive flow,the stress tensor was analyzed to explore the micro-cutting force of the Abrasive Flow Machining(AFW)process.It points out that the abrasive flow precision machining is a combined machining method made by extrusion and micro removal,and the micro-cutting force of the AFW is come from a combination of medium share force,squeezing force and plowing force.The dynamics model was established and general change law of the micro-cutting force in AFW processing were revealed quantitatively by changing processing conditions and processing parameters,such as the pressure of contact region,removal amounts and surface roughness.Finally,the shear force was simulated numerically by using the CFD module of COMSOL multiphysics software.The experiment results show that the mold core is conductive to increasing the micro-cutting force,the surface roughness Raof the solider(number four)has decreased from 2.918μm to 1.027μm and the removal is 0.09 g after 15 processing cycles.The results demonstrate that the removal is changed in the abrasive flow machining process,however,the removal action is quickweakened with the increase of the times of extrusion and the surface roughness is still improved.
引文
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[2]居志兰,朱永伟,王建彬,等.抛光介质对固结磨料化学机械抛光水晶的影响[J].光学精密工程,2013,21(4):955-962.JU ZH L,ZHU Y W,WANG J B,et al..Effect of slurries on chemical mechanical polishing of decorative glasses by fixed-abrasive pad[J].Opt.Precision Eng.,2013,21(4):955-962.(in Chinese)
[3]计时鸣,唐波,谭大鹏,等.结构化表面软性磨粒流精密光整加工方法及其磨粒流动力学数值分析[J].机械工程学报,2010,46(15):178-184.JI SH M,TANG B,TAN D P,et al..Structured surface softness abrasive flow precision finish machining and its abrasive flow dynamic numerical analysis[J].Chinese Journal of Mechanical Engineering,2010,46(15):178-184.(in Chinese)
[4]计时鸣,李琛,谭大鹏,等.基于Preston方程的软性磨粒流加工特性[J].机械工程学报,2011,47(17):156-163.JI SH M,LI CH,TAN D P,et al..Study on machinability of softness abrasive flow based on preston equation[J].Chinese Journal of Mechanical Engineering,2011,47(17):156-163.(in Chinese)
[5]RAVI SANKAR M,JAIN V K,RAMKUMA J,et al..Rheological characterization of styrene-butadiene based medium and its finishing performance using rotational abrasive flow finishing process[J].International Journal of Machine Tools and Manufacture,2011,51:947-957.
[6]RHOADES L J.Abrasive flow machining:a case study[J].Journal of Material Processing Technology,1991,28:107-116.
[7]LOVELESS T R,WILLIAMS R E,RAJURKAR K P.A study of the effects of abrasive flow finishing on various machined surfaces[J].Journal of Material Processing Technology,1994,47:133-151.
[8]WILLIAMS R E,RAJURKAR K P.Stochastic modeling and analysis of abrasive flow machining[J].Journal of Engineering for Industry(Transactions of the ASME),1992,114:74-81.
[9]WILLIAMS R E.Acoustic emission characteristics of abrasive flow machining[J].Transactions of the ASME120,1998,264-271.
[10]计时鸣,马宝丽,谭大鹏.结构化表面环境下软磨粒流的流场数值分析[J].光学精密工程,2011,19(9):2092-2099JI SH M,MA B L,TAN D P,et al..Numerical analysis of soft abrasive flow in structured restraint flow passage[J].Opt.Precision Eng.,2011,19(9):2092-2099.(in Chinese)
[11]丁金福,张克华,许永超,等.摆线泵内转子的磨粒流均匀化抛光方法及实验研究[J].排灌机械工程学报,2013,31(7):45-53.DING J F,ZHANG K H,XU Y CH,et al..Abrasive flow homogenization polishing method and processing experiment for cycloidal pump Inner rotor[J].Journal of Drainage and Irrigation Machinery Engineering,2013,31(7):45-53.(in Chinese)
[12]黄卫星,李建明,肖泽仪.工程流体力学[M].北京:化学工业出版社,2011.HUANG W X,LI J M,XIAO Z Y.Engineering Fluid Mechanics[M].Beijing:Chemical Industry Press,2011.(in Chinese)
[13]董志国,轧刚,李元宗.磨粒流载体在圆管流动中的壁面滑动特性分析[J].太原理工大学学报,2011,42(2):160-163.DONG ZH G,YA G,LI Y Z.Analysis of wall sliding characteristics about abrasive flow carrier in pipe[J].Journal of Taiyuan University of Technology,2011,42(2):160-163.(in Chinese)
[14]董志国,轧刚,宋桂珍,等.磨粒流加工中磨料黏弹性对磨削效果的影响分析[J].金刚石与磨料磨具工程,2010,30(6):82-85.DONG ZH G,YA G,SONG G ZH,et al..Influence of viscoelasticity on grinding effect in abrasive flow machining[J].Diamond&Abrasives Engineering,2010,30(6):82-85.(in Chinese)
[15]B.布尚,葛世荣.摩擦学导论[M].北京:机械工业出版社,2007.BHARAT BHUSHAN,GE SH R.Introduction of Tribology[M].Beijing:Machinery Industry Press,2007.(in Chinese)