磁粒研磨Al 2024细长管的机理及试验研究
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摘要
目的探究磁粒研磨过程中外部磁极的不同排布方式对Al 2024细长管内表面研磨质量的影响,寻求一种最佳的磁极排布方式。方法首先,在理论上分析了磁粒研磨细长管的基本原理;其次,利用ANSYS软件的磁场模块对磁极的三种排布方式进行模拟,得出不同的磁感应强度曲线,通过分析曲线的变化规律来探讨磁极排布方式对研磨效果的影响;再次,设计了试验装置,对理论和有限元仿真结果进行了验证试验,通过观测内表面粗糙度值和微观形貌,对比了试验效果。结果随着磁极夹角从90?增大到180?,磁感应强度逐渐减小,有效磁场区域逐渐减小。较小的磁感应强度使得磁性磨粒在磁场中受到的研磨压力变小,磁性磨粒易于受离心力作用甩出加工区域,参与研磨的数量变少,研磨质量降低;变小的有效磁场区域使得磁性磨粒受力区域减小,被磁化的数量减少,参与研磨的数量减少,研磨质量较差。研磨时间10 min后,从试验结果中可以看出,当磁极90?分布时,表面粗糙度值下降最大,从原来的0.66μm降至0.12μm,表面的凹坑和纹理缺陷被去除,表面形貌均匀且光泽度较好。结论磁粒研磨Al 2024细长管内表面时,调整磁极排布可以提高加工区域的磁感应强度和增大有效磁场区域面积,继而提高磁性磨粒的作用效果,促进研磨的有效进行,保证较好的研磨质量。
The work aims to investigate the effects of different magnetic pole arrangement ways of external magnetic poles on grinding quality of internal surface on Al 2024 slender tube during magnetic particle grinding, so as to seek the best way of magnetic pole arrangement. Firstly, basic principle of magnetic particle grinding for slender tube was analyzed theoretically; secondly, magnetic field module of ANSYS software was used to simulate three magnetic pole arrangement ways and obtain different magnetic induction intensity curves. The influences of magnetic pole arrangement ways on grinding effect were investigated by analyzing variation of the curves; thirdly, experimental device was designed, and verification test was applied to the theory and finite element simulation results. The test results were compared by observing roughness and micromorphology of the internal surface. As the angle between the magnetic poles increases from 90? to 180?, the magnetic induction intensity decreased and effective magnetic field areas decreased gradually; the magnetic induction intensity was smaller, so grinding pressure sustained by magnetic particles in magnetic field was smaller, magnetic particles were easily flung out of processing area under the action of centrifugal force. The number of magnetic particles involved in grinding was decreased and grinding quality was reduced. Under the effects of smaller effective magnetic field area, stressed area of magnetic particles was decreased, quantity of magnetized particles was reduced, number of magnetic particles involved in grinding was reduced, and grinding quality was degraded. While the magnetic pole was arranged at the angle of 90?, the result of 10 min grinding test showed that surface roughness decreased most sharply from the original Ra 0.66 μm to Ra 0.12 μm, surface pits and texture defects were removed, surface morphology was uniform, and glossiness was better. During magnetic particle grinding of internal surface on Al 2024 slender tube, adjusting magnetic pole arrangement can improve magnetic induction intensity and effective magnetic field area of the processing area, and then improve the effect of magnetic abrasive particles, promote effective grinding and guarantee better grinding quality.
The work aims to investigate the effects of different magnetic pole arrangement ways of external magnetic poles on grinding quality of internal surface on Al 2024 slender tube during magnetic particle grinding, so as to seek the best way of magnetic pole arrangement. Firstly, basic principle of magnetic particle grinding for slender tube was analyzed theoretically; secondly, magnetic field module of ANSYS software was used to simulate three magnetic pole arrangement ways and obtain different magnetic induction intensity curves. The influences of magnetic pole arrangement ways on grinding effect were investigated by analyzing variation of the curves; thirdly, experimental device was designed, and verification test was applied to the theory and finite element simulation results. The test results were compared by observing roughness and micromorphology of the internal surface. As the angle between the magnetic poles increases from 90? to 180?, the magnetic induction intensity decreased and effective magnetic field areas decreased gradually; the magnetic induction intensity was smaller, so grinding pressure sustained by magnetic particles in magnetic field was smaller, magnetic particles were easily flung out of processing area under the action of centrifugal force. The number of magnetic particles involved in grinding was decreased and grinding quality was reduced. Under the effects of smaller effective magnetic field area, stressed area of magnetic particles was decreased, quantity of magnetized particles was reduced, number of magnetic particles involved in grinding was reduced, and grinding quality was degraded. While the magnetic pole was arranged at the angle of 90?, the result of 10 min grinding test showed that surface roughness decreased most sharply from the original Ra 0.66 μm to Ra 0.12 μm, surface pits and texture defects were removed, surface morphology was uniform, and glossiness was better. During magnetic particle grinding of internal surface on Al 2024 slender tube, adjusting magnetic pole arrangement can improve magnetic induction intensity and effective magnetic field area of the processing area, and then improve the effect of magnetic abrasive particles, promote effective grinding and guarantee better grinding quality.
引文
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[3]胡海涛,李玉龙,索涛,等.2024铝合金振动疲劳特性及断口分析[J].航空材料学报,2013,33(4):78-83.HU Hai-tao,LI Yu-long,SUO Tao,et al.Vibration fatigue and fracture performance of aluminum alloy 2024[J].Journal of aeronautical materials,2013,33(4):78-83.
[4]李晓宁.2024高强度航空铝合金耐蚀性及断裂行为数值模拟研究[D].天津:天津理工大学,2015.LI Xiao-ning.Numerical simulation of corrosion resistance and fracture behavior of 2024 aerospace aluminum alloy[D].Tianjin:Tianjin University of Technology,2015.
[5]马慧娟,顾艳红,车俊铁,等.表面纳米化对2024铝合金耐磨性能的影响[J].材料保护,2016,49(7):56-59.MA Hui-juan,GU Yan-hong,CHU Jun-tie,et al.Effect of surface nanocrystallization on wear resistance of 2024 aluminum alloy[J].Materials protection,2016,49(7):56-59.
[6]董佳怡.表面纳米化对金属材料耐磨性的影响[J].新材料新装饰,2014(7):119-123.DONG Jia-yi.Influence of surface nanocrystal lization on wear resistance of metallic materials[J].New materials new decoration,2014(7):119-123.
[7]陈燕,张耀明,邓超,等.V形磁铁在SUS304管内表面抛光中的应用[J].机械工程学报,2014,50(15):187-191.CHEN Yan,ZHANG Yao-ming,DENG Chao,et al.Application of V-shaped magnet in polishing the inner surface of the SUS304 tubing[J].China mechanical engineering,2014,50(15):187-191.
[8]陈燕,宋宗朋,李昌,等.磁研磨法抛光40Cr钢工件内表面的影响因素[J].中国表面工程,2015,28(4):62-69.CHEN Yan,SONG Zong-peng,LI Chang,et al.Influencing factors on polishing inner surface of 40Cr steel pipe fittings with a magnetic grinding method[J].China surface engineering,2015,28(4):62-69.
[9]韩冰,刘立鑫,陈燕.磁力研磨法加工弯管内表面的工艺参数优化[J].中国机械工程,2015(6):814-817.HAN Bing,LIU Li-xin,CHEN Yan.Optimization of process parameters on magnetic abrasive finishing to inner surface of bending pipe[J].China mechanical engineering,2015(6):814-817.
[10]ZOU Y H,JIAO A Y,AIZAWA T.Study on plane magnetic abrasive finishing process-experimental and theoretical analysis on polishing trajectory[J].Advanced materials research,2010,126-128:1023-1028.
[11]JIAO A Y,QUAN H J,LI Z Z,et al.Study on improving the trajectory to elevate the surface quality of plane magnetic abrasive finishing[J].The international journal of advanced manufacturing technology,2015:1-11.
[12]张琳,赵吉宾,李论.复杂曲面磁粒研磨加工方法研究[J].组合机床与自动化加工技术,2014(1):129-131.ZHANG Lin,ZHAO Ji-bin,LI Lun.Magnetic abrasive finishing method research of complex curved surface[J].Machinery&automatic manufacturing technology,2014(1):129-131.
[13]KIM S O,KWAK J S.Magnetic force improvement and parameter optimization for magnetic abrasive polishing of AZ31 magnesium alloy[J].The Chinese journal of nonferrous metals,2008,18(s1):369-373.
[14]韩冰,邓超,陈燕.球形磁铁在弯管内表面磁力研磨中的应用[J].摩擦学学报,2013,33(6):565-570.HAN Bing,DENG Chao,CHEN Yan.Spherical magnet processing of inner surface of bending pipe by magnetic abrasive finishing[J].Tribology,2013,33(6):565-570.
[15]CHANG G W,YAN B H,HSU R T.Study on cylindrical magnetic abrasive finishing using unbonded magnetic abrasives[J].International journal of machine tools and manufacture,2002,42(5):575-583.