超硬磨料砂轮修整技术综述与展望
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摘要
超硬磨料磨具以其优异的磨削性能获得机械加工领域普遍认可,但制约其进一步拓展应用的主要原因之一是超硬砂轮修整极其困难。面对此难题,作者梳理目前超硬砂轮在工程应用中的主要修整方法,分析其工作原理、技术演变、主要特点、应用状况,对先进修整技术进行阐述,最后总结并展望三大结合剂超硬砂轮实用修整技术及发展趋势。金属结合剂超硬砂轮大余量去除基本锁定为电火花放电修整,小余量修整主要以普通磨具磨削法修整为主,细粒度超硬砂轮采用在线电解修整优势明显;陶瓷结合剂超硬砂轮简单直线修整逐渐被点轮修整取代,高陡度成型砂轮修整仍是金刚石滚轮;树脂结合剂超硬砂轮多以磨削法修整为主,但科学实用修整技术仍需进一步研发。激光修整具有非接触、高效、便利、易控、超长寿命等优点,具有更加广阔的发展前景;集机、电、声、热、化等多种方法于一体的复合修整也是超硬砂轮技术人员一直关注和研发的重点。
Superhard abrasive tools have been widely recognized in the field of mechanical processing for their excellent grinding performance, but one of the main reasons restricting their further development and application is the extremely difficult dressing of superhard grinding wheels. To solve the problem, this paper combs the main dressing methods in the application of superhard grinding wheel at present, and analyzes the working principle, technical evolution, main characteristics and application status.The advanced dressing technology is expounded. Finally, the practical dressing technology and development trend of three binders for superhard grinding wheel are summarized and prospected. The large margin removal of metal bond superhard grinding wheel is basically locked in the electric spark discharge dressing, the small margin dressing is mainly the common grinding tool grinding method, the fine grain superhard grinding wheel has the advantage of on?line electrolytic dressing. The simple straight?line dressing of ceramic bond superhard grinding wheel will gradually be replaced by point wheel dressing, and the dressing of high steepness molding grinding wheel will still be occupied by diamond roller. Resin?bonded superhard grinding wheel is mainly used for grinding dressing, but the scientific and practical dressing technology will be the main direction for further research and development in the future. Laser dressing has the advantages of non?contact, high efficiency, convenience, easy control and long life, etc. The combination dressing that integrates machine, electricity, sound, heat and chemical methods is also the focus of attention.
Superhard abrasive tools have been widely recognized in the field of mechanical processing for their excellent grinding performance, but one of the main reasons restricting their further development and application is the extremely difficult dressing of superhard grinding wheels. To solve the problem, this paper combs the main dressing methods in the application of superhard grinding wheel at present, and analyzes the working principle, technical evolution, main characteristics and application status.The advanced dressing technology is expounded. Finally, the practical dressing technology and development trend of three binders for superhard grinding wheel are summarized and prospected. The large margin removal of metal bond superhard grinding wheel is basically locked in the electric spark discharge dressing, the small margin dressing is mainly the common grinding tool grinding method, the fine grain superhard grinding wheel has the advantage of on?line electrolytic dressing. The simple straight?line dressing of ceramic bond superhard grinding wheel will gradually be replaced by point wheel dressing, and the dressing of high steepness molding grinding wheel will still be occupied by diamond roller. Resin?bonded superhard grinding wheel is mainly used for grinding dressing, but the scientific and practical dressing technology will be the main direction for further research and development in the future. Laser dressing has the advantages of non?contact, high efficiency, convenience, easy control and long life, etc. The combination dressing that integrates machine, electricity, sound, heat and chemical methods is also the focus of attention.
引文
[1]王先逵.精密加工技术实用手册[M].北京:机械工业出版社,2001:125-135.
[2]JACKSON M J,DAVIM J P.Machining with abrasives[M].New York:Springer,2011:1-9.
[3]TONSHOFF H K.Grinding process achievements and their consequences on machine tools challenges and opportunities[J].CIRP Annals-Manufacturing Technology,1998,47(14):651-668.
[4]王光祖,刘金昌.绿色制造与超硬制品的开发应用[J].超硬材料工程,2011,23(4):39-42.
[5]邹文俊.中国超硬材料与制品的发展与思考[J].超硬材料工程,2016,28(2):45-49.
[6]周金龙.机床行业的发展对磨料磨具产品的需求变化-CIMT2015展会述评[J].世界制造技术与装备市场,2015,(5):64-65.
[7]磨商网.金刚石等超硬材料制品新产品开发方向是什么[EB/OL].[2018-08-04].http://news.momo35.com/2018/05/15085973080.html.
[8]人民网政务.中国与德日高端机床制造技术相差距20年[EB/OL].[2018-08-04].http://www.jc35.com/news/detail/65292.html.
[9]崔仲鸣,赫青山,冯创举,等.超硬磨料磨具修整技术研究[J].金刚石与磨料磨具工程,2016,36(1):43-49.
[10]WEGENER K,HOFFMEISTER H W,KARPUSCHEWSKIB,et al.Conditioning and monitoring of grinding wheels[J].CIRPAnnals-Manufacturing Technology,2011(60):757-777.
[11]刘月明,李建勇,沈海阔,等.单点修整工具磨损对砂轮磨削表面的影响[J].摩擦学报,2014,34(5):497-503.
[12]冯克明,崔恒泰.多晶金刚石修整工具磨损的试验研究[J].精密制造与自动化,1992(2):40-41.
[13]迟玉伦,李郝林,岳泰.修整金刚笔磨损智能预测方法研究[J].系统仿真学报,2017,29(6):1210-1217.
[14]DENNIS P,KAISER M.用可修整的金刚石和立方氮化硼砂轮进行成形磨削[J].机械工程师,2001(7):69-71.
[15]朱弘,徐载熊.超硬砂轮修整的研究-制动式整形器的理论与实践[J].中国纺织大学学报,1993,19(3):59-64.
[16]王先逵,应宝阁.金刚石微粉砂轮软弹性修整研究-软弹性修整法及其机理[J].金刚石与磨料磨具工程,1995,90(6):7-11.
[17]刘利.用磨料喷射研磨法修整砂轮[J].机械制造,1994(6):40.
[18]赵清亮,赵玲玲,王宇,等.电镀金刚石砂轮高效精密修整及熔融石英磨削试验研究[J].机械工程学报,2013,49(23):176-181.
[19]仇中军,邹大程,闫广鹏.基于修整力的树脂结合剂金刚石砂轮机械修整[J].光学精密工程,2015,23(4):996-1003.
[20]GHOSH A,CHATTOPADHYAY A K.Experimental investigation on performance of touch-dressed single-layer brazed CBN wheels[J].International Journal of Machine Tools&Manufacture,2007,47(7):1206-1213.
[21]CUI Zm,LIU Nf.Technique and application about diamond dressing roller[J].Key Engineering Materials,2006(2):52-56.
[22]赵金坠,冯克明,朱建辉,等.不同修锐工具对树脂结合剂CBN砂轮修锐效果的影响[J].工具技术,2016,50(12):82-85
[23]庄司克雄.陶瓷结合剂金刚石砂轮的修整研究-各种修整方法的修整效果比较[J].金刚石与磨料磨具工程,1992,71(5):6-12.
[24]梁志强,吴立飞,周天丰,等.金刚石砂轮V形尖端切向磨削修整试验研究[J].机械工程学报,2018,54(3):196-202.
[25]徐湘涛.金刚石修整滚轮技术[J].超硬材料工程,2006,18(3):31-35.
[26]赵捷,高国富.超硬磨料砂轮超声振动修整新进展[J].金刚石与磨料磨具工程,2010,176(2):79-83.
[27]SUZUKI K,UEMATSU T,NAKAGAWA T.On-machine truing/dressing of metal bond grinding wheels by electro-discharge machining[J].CIRP Annals-Manufacturing Technology,1987,36(1):115-118.
[28]刘忠德,张飞虎,王凯,等.电火花修整金属基圆弧砂轮表面形貌的实验研究[J].金刚石与磨料磨具工程,2016,36(5):32-37.
[29]OHMORI H,NAKAGAWA T.Utilization of nonlinear conditions in precision grinding with ELID(electrolytic in-process dressing)for fabrication of hard material components[J].CIRP Annals-Manufacturing Technology,1997,46(1):261-264.
[30]伍俏平,王煜,瞿为,等.在线电解修整磨削液研究现状及其展望[J].中国机械工程,2017,28(9):1118-1125.
[31]BABU N R,RADHAKRISHNAN V.Surface topography of a laser dressed grinding wheel[J].ASME,Production Engineering Division(Publication)PED,1988,34:199-212.
[32]邓辉.纳秒激光修整粗粒度金刚石砂轮及其磨削性能研究[J].兵器材料科学与工程,2017,40(3):21-24.
[33]邓辉,陈根余,周聪,等.超硬磨料砂轮激光修整技术的现状与展望[J].强激光与粒子束,2014,26(7):309-314.
[34]徐旺,苏宏华,徐九华,等.碟轮修整单层钎焊金刚石砂轮的试验研究[J].金刚石磨料磨具工程,2012,32(1):38-41.
[35]冯克明,师超钰,朱建辉,等.单层磨料砂轮修整及修整阈值控制试验研究[J].机械工程学报,2018,54(13):225-232.
[36]郑州磨料磨具磨削研究所有限公司.一种超硬磨料砂轮快速高效整形方法:中国,201510403745.7[P].2015-11-25.
[37]王楠.磨削机床砂轮修整专利技术分析[J].金属加工(冷加工),2017(19):22-23.
[38]黄震,安政伟,赵金伟.陶瓷CBN砂轮修整参数的量化分析研究[J].金刚石磨料磨具工程,2017,37(1):65-68.
[39]董鹏敏,田宝,周海洋.国产CBN砂轮高速磨削工艺[J].现代制造工程,2018(2):99-101.
[40]郑州磨料磨具磨削研究所有限公司.一种基于流体动压驱动的砂轮修整方法及装置:中国,2017109726972[P].2018-03-06.
[2]JACKSON M J,DAVIM J P.Machining with abrasives[M].New York:Springer,2011:1-9.
[3]TONSHOFF H K.Grinding process achievements and their consequences on machine tools challenges and opportunities[J].CIRP Annals-Manufacturing Technology,1998,47(14):651-668.
[4]王光祖,刘金昌.绿色制造与超硬制品的开发应用[J].超硬材料工程,2011,23(4):39-42.
[5]邹文俊.中国超硬材料与制品的发展与思考[J].超硬材料工程,2016,28(2):45-49.
[6]周金龙.机床行业的发展对磨料磨具产品的需求变化-CIMT2015展会述评[J].世界制造技术与装备市场,2015,(5):64-65.
[7]磨商网.金刚石等超硬材料制品新产品开发方向是什么[EB/OL].[2018-08-04].http://news.momo35.com/2018/05/15085973080.html.
[8]人民网政务.中国与德日高端机床制造技术相差距20年[EB/OL].[2018-08-04].http://www.jc35.com/news/detail/65292.html.
[9]崔仲鸣,赫青山,冯创举,等.超硬磨料磨具修整技术研究[J].金刚石与磨料磨具工程,2016,36(1):43-49.
[10]WEGENER K,HOFFMEISTER H W,KARPUSCHEWSKIB,et al.Conditioning and monitoring of grinding wheels[J].CIRPAnnals-Manufacturing Technology,2011(60):757-777.
[11]刘月明,李建勇,沈海阔,等.单点修整工具磨损对砂轮磨削表面的影响[J].摩擦学报,2014,34(5):497-503.
[12]冯克明,崔恒泰.多晶金刚石修整工具磨损的试验研究[J].精密制造与自动化,1992(2):40-41.
[13]迟玉伦,李郝林,岳泰.修整金刚笔磨损智能预测方法研究[J].系统仿真学报,2017,29(6):1210-1217.
[14]DENNIS P,KAISER M.用可修整的金刚石和立方氮化硼砂轮进行成形磨削[J].机械工程师,2001(7):69-71.
[15]朱弘,徐载熊.超硬砂轮修整的研究-制动式整形器的理论与实践[J].中国纺织大学学报,1993,19(3):59-64.
[16]王先逵,应宝阁.金刚石微粉砂轮软弹性修整研究-软弹性修整法及其机理[J].金刚石与磨料磨具工程,1995,90(6):7-11.
[17]刘利.用磨料喷射研磨法修整砂轮[J].机械制造,1994(6):40.
[18]赵清亮,赵玲玲,王宇,等.电镀金刚石砂轮高效精密修整及熔融石英磨削试验研究[J].机械工程学报,2013,49(23):176-181.
[19]仇中军,邹大程,闫广鹏.基于修整力的树脂结合剂金刚石砂轮机械修整[J].光学精密工程,2015,23(4):996-1003.
[20]GHOSH A,CHATTOPADHYAY A K.Experimental investigation on performance of touch-dressed single-layer brazed CBN wheels[J].International Journal of Machine Tools&Manufacture,2007,47(7):1206-1213.
[21]CUI Zm,LIU Nf.Technique and application about diamond dressing roller[J].Key Engineering Materials,2006(2):52-56.
[22]赵金坠,冯克明,朱建辉,等.不同修锐工具对树脂结合剂CBN砂轮修锐效果的影响[J].工具技术,2016,50(12):82-85
[23]庄司克雄.陶瓷结合剂金刚石砂轮的修整研究-各种修整方法的修整效果比较[J].金刚石与磨料磨具工程,1992,71(5):6-12.
[24]梁志强,吴立飞,周天丰,等.金刚石砂轮V形尖端切向磨削修整试验研究[J].机械工程学报,2018,54(3):196-202.
[25]徐湘涛.金刚石修整滚轮技术[J].超硬材料工程,2006,18(3):31-35.
[26]赵捷,高国富.超硬磨料砂轮超声振动修整新进展[J].金刚石与磨料磨具工程,2010,176(2):79-83.
[27]SUZUKI K,UEMATSU T,NAKAGAWA T.On-machine truing/dressing of metal bond grinding wheels by electro-discharge machining[J].CIRP Annals-Manufacturing Technology,1987,36(1):115-118.
[28]刘忠德,张飞虎,王凯,等.电火花修整金属基圆弧砂轮表面形貌的实验研究[J].金刚石与磨料磨具工程,2016,36(5):32-37.
[29]OHMORI H,NAKAGAWA T.Utilization of nonlinear conditions in precision grinding with ELID(electrolytic in-process dressing)for fabrication of hard material components[J].CIRP Annals-Manufacturing Technology,1997,46(1):261-264.
[30]伍俏平,王煜,瞿为,等.在线电解修整磨削液研究现状及其展望[J].中国机械工程,2017,28(9):1118-1125.
[31]BABU N R,RADHAKRISHNAN V.Surface topography of a laser dressed grinding wheel[J].ASME,Production Engineering Division(Publication)PED,1988,34:199-212.
[32]邓辉.纳秒激光修整粗粒度金刚石砂轮及其磨削性能研究[J].兵器材料科学与工程,2017,40(3):21-24.
[33]邓辉,陈根余,周聪,等.超硬磨料砂轮激光修整技术的现状与展望[J].强激光与粒子束,2014,26(7):309-314.
[34]徐旺,苏宏华,徐九华,等.碟轮修整单层钎焊金刚石砂轮的试验研究[J].金刚石磨料磨具工程,2012,32(1):38-41.
[35]冯克明,师超钰,朱建辉,等.单层磨料砂轮修整及修整阈值控制试验研究[J].机械工程学报,2018,54(13):225-232.
[36]郑州磨料磨具磨削研究所有限公司.一种超硬磨料砂轮快速高效整形方法:中国,201510403745.7[P].2015-11-25.
[37]王楠.磨削机床砂轮修整专利技术分析[J].金属加工(冷加工),2017(19):22-23.
[38]黄震,安政伟,赵金伟.陶瓷CBN砂轮修整参数的量化分析研究[J].金刚石磨料磨具工程,2017,37(1):65-68.
[39]董鹏敏,田宝,周海洋.国产CBN砂轮高速磨削工艺[J].现代制造工程,2018(2):99-101.
[40]郑州磨料磨具磨削研究所有限公司.一种基于流体动压驱动的砂轮修整方法及装置:中国,2017109726972[P].2018-03-06.