高速深磨（HSDG）工艺中关键应用技术的研究与开发
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摘要
工程陶瓷具有高强度、高硬度、高耐热性、高耐磨性、高耐腐蚀性等优异特性,在工业领域中的应用日益广泛。然而,它的高硬度和高脆性也给其加工带来了很大困难,也因此加工成本比普通金属材料显著增加。磨削是工程陶瓷的主要加工工艺,磨削成本在整个加工成本中占了绝大部分份额。因此,提高磨削效率,可极大地降低加工成本。
近几十年来,对于高速超高速磨削所带来的技术优势和经济效益,人们给予了充分的注意和重视。砂轮线速度的提高能够大大地减小单磨粒未变形切屑厚度,进而减小磨削力,改善加工表面质量,提高材料磨除率,实现高效加工。高速深磨(High Speed Deep Grinding,简称HSDG)工艺是其主要形式之一,它集高的砂轮线速度和大切深于一体,既能达到高的金属切除率,又能保证加工表面高质量的一种加工工艺。然而,工程陶瓷的硬脆难加工特性也给高速深磨技术带来了新的难题:加工中大磨削力与高磨削温度使加工条件急剧恶化,砂轮磨损因此加剧,进而发生钝化并渐失切削性能,加工质量也随之恶化。因此,在工程陶瓷的高速深磨过程中,保证砂轮磨粒始终处于稳定的切削状态显得尤为重要。文献分析和研究表明,在线电解修锐(Electrolytic in-process dressing,简称ELID)技术是保持磨粒切削稳定的有效方式,但是,将ELID技术应用于工程陶瓷的高速深磨(即高速深磨ELID)时,由此导致的一系列新问题亟待解决。这一系列问题的关键是如何提高工程陶瓷粗磨砂轮的ELID效率,并保持砂轮在高速深磨中的切削稳定性。此外,在高速深磨时,砂轮线速度的强化了磨削区附近的气障,从而影响到磨削液的有效注入,使磨削温度升高,进而影响磨削环境和加工质量。
本课题针对以上问题,重点研究了工程陶瓷等硬脆难加工材料高速深磨所必需的三项关键技术,即金属结合剂金刚石砂轮的整形技术、在线电解修锐(ELID)技术和磨削液注入技术,所取得的成果总结如下:
1)针对较粗粒度的金属结合剂金刚石砂轮无法单纯依靠电火花整形来实现整形的问题,本文提出了砂轮电火花—机械复合整形法。先利用电火花整形法去除砂轮偏心部分的金属结合剂,降低其对砂轮磨粒的把持强度:再以机械整形法去除偏心部分突出的磨粒。如此交替采用电火花与碳化硅滚轮对砂轮进行整形,直至砂轮达到整形精度要求为止。以此方法对100/120#青铜结合剂金刚石砂轮进行整形试验,试验结果表明它能够有效地解决较粗粒度金属结合剂砂轮的整形效率低的问题,整形精度可提高到6μm左右。
2)为改善ELID预修锐阶段的效率问题,本文增加了机械预修锐环节,以及时去除电解预修锐在砂轮表面所形成的氧化膜,恢复电解能力,从而使砂轮磨粒的突出高度尽快达到最佳切削高度。此外,本文还以砂轮磨粒突出高度保持不变为控制条件,建立了ELID稳定磨削阶段的控制模型,从而解决了工程陶瓷高速深磨ELID磨削时砂轮表面很难形成致密连续氧化膜而引起磨削过程不稳定的难题。
3)针对工程陶瓷高速深磨ELID磨削时ELID效率低下的问题,本文开发了封闭式电解阴极,并以此为核心构建了高速深磨ELID磨削试验平台,包括磨床、砂轮、电解装置、电源等部分;还对电解液的成膜性能进行了研究,开发出适用于青铜结合剂砂轮的ELID专用电解液。封闭式阴极与传统式阴极电解预修锐对比试验表明采用封闭式电解阴极可获得较高的电解电流,尤其是在砂轮线速度为150m/s时分别采用两阴极的电流差值可达1.1A,这充分表明了封闭式电解阴极在高速超高速磨削中的作用效果。
4)对氧化锆陶瓷分别进行高速深磨ELID与非ELID高速深磨工艺试验,试验结果表明ELID技术的应用增加了砂轮表面的有效磨刃密度,改善了砂轮的切削状态,从而使磨削力减小到3/4,表面粗糙度值减小0.15μm左右。
5)本文还提出一种新的磨削液注入方式,依此方式设计出了一种新型喷嘴——封闭式Y型喷嘴,并通过高速深磨试验验证了喷嘴的作用效果。试验结果表明:相对于普通L型喷嘴,采用封闭式Y型喷嘴供液能使工件得到更好的冷却,从而增加了工件材料磨除率;它还能及时清洗砂轮,使其处于良好的切削状态,有效地改善工件表面的加工质量。
Advanced engineering ceramics have been extensively used as structural materials in modern manufacturing industries due to their excellent properties,such as high hardness at both ambient and elevated temperatures,low thermal expansion, and excellent wear resistance and chemical inertness.Nevertheless,the high hardness and brittleness also make the machining of the ceramics very difficult.As a result,the machining process is associated with a high cost.Grinding is a commonly used machining process for engineering ceramics.Therefore,the improvement of efficiency in ceramics grinding shall greatly reduce the total machining cost.
In the past decades,a great attention has been paid to the development of high speed grinding technologies.In a high speed grinding process,the increase in grinding wheel velocity can significantly reduce the undeformed chip thickness per grit,and thus decrease the grinding force.This enables the improvement of ground surface quality and the elevation of material removal rate.High speed deep grinding (HSDG) is a process which integrated with high grinding velocity and large depth of cut in order to achieve high material removal rate while maintaining a high surface quality.
The HSDG of ceramics is often accompanied with large grinding force and high grinding temperature.The deterioration of machining conditions thus accelerates the wear of the grinding wheel.Therefore,the active abrasives quickly lose their cutting abilities,and the machining quality is deteriorated.It is thus important to keep active abrasives in good cutting condition throughout the HSDG grinding process.Previous investigations have shown that electrolytic in-process dressing(ELID) is a good approach for continuously maintain the grit sharpness during grinding.However, this technique was mainly used for dressing the fine abrasive wheels.Several technical issues need to be resolved if the ELID technology is applied to a HSDG process for engineering ceramics.The key issue is how to maintain the ELID efficiency during a HSDG process.In a HSDG process,the increasing wheel velocity strengthens the air barrier around the grinding wheel,which affects the impinging of grinding fluid,thus results in low ELID efficiency and high grinding temperature.
This project focused on the developments of key technologies for the HSDG of engineering ceramics,which tackled the key issues mentioned earlier.The technologies included the truing and ELID dressing for metal-bond diamond wheels, and the coolant supply technology.The significant results achieved are summarized below.
1) It is challenging to true metal-bond diamond wheels with coarse abrasives directly using the electrical discharge truing(EDT).In this project,the electrical discharge/mechanical hybrid truing method was developed.In this new truing method,the bond material on the wheel surface was firstly removed by EDT, which also lowered the holding strength of the grits.The protruded abrasive grits was then abraded by mechanical removal.EDT and mechanical truing were carried out alternately until the wheel may meet the grinding requirements.Using this method,the coarser abrasive metal bonded wheels were efficiently trued,with a roundness error of smaller than 6μm.
2) Mechanical pre-dressing was introduced into the ELID pre-dressing process. Using this approach,the oxide layer formed on the wheel surface was removed,and the electrical current during ELID pre-dressing was enhanced.This has significantly increased the pre-dressing efficiency.Additionally,a control model was also established,which effectively controlled the balance of metal bonded removal and wear of grinding wheel,and maintained the protrusion height of grits as a constant.
3) A new electrolysis cathode was successfully developed and used as a core component in the HSDG-ELID system.The application of such a cathode has solved a long-standing problem,which is the low ELID efficiency at relatively high grinding speeds.The comparison between the closed and the conventional cathodes demonstrated that a much higher pre-dressing current,hence an improved ELID efficiency was obtained.In addition,a new electrolytic fluid specifically for dressing bronze-bond diamond wheels was developed,which enhanced the ELID efficiency as well.The comparison between the HSDG processes with and without ELID showed that ELID technology increased the number of effective cutting grits on the wheel surface and improved their cutting abilities,resulting in a decreased grinding force and improved surface roughness.
4) A new coolant supply method was developed.This was accompanied with the design and fabrication of a closed Y-type nozzle.The HSDG experiments using the Y-type nozzle and the conventional L-type nozzle indicated that the closed Y-type nozzle improved the cooling conditions in the grinding zone,which enabled a higher materials removal rate.Additionally,the use of the new nozzle could better clean the wheel.This helped to maintain the wheel in a stable cutting condition and thus improve the quality of grinding.
近几十年来,对于高速超高速磨削所带来的技术优势和经济效益,人们给予了充分的注意和重视。砂轮线速度的提高能够大大地减小单磨粒未变形切屑厚度,进而减小磨削力,改善加工表面质量,提高材料磨除率,实现高效加工。高速深磨(High Speed Deep Grinding,简称HSDG)工艺是其主要形式之一,它集高的砂轮线速度和大切深于一体,既能达到高的金属切除率,又能保证加工表面高质量的一种加工工艺。然而,工程陶瓷的硬脆难加工特性也给高速深磨技术带来了新的难题:加工中大磨削力与高磨削温度使加工条件急剧恶化,砂轮磨损因此加剧,进而发生钝化并渐失切削性能,加工质量也随之恶化。因此,在工程陶瓷的高速深磨过程中,保证砂轮磨粒始终处于稳定的切削状态显得尤为重要。文献分析和研究表明,在线电解修锐(Electrolytic in-process dressing,简称ELID)技术是保持磨粒切削稳定的有效方式,但是,将ELID技术应用于工程陶瓷的高速深磨(即高速深磨ELID)时,由此导致的一系列新问题亟待解决。这一系列问题的关键是如何提高工程陶瓷粗磨砂轮的ELID效率,并保持砂轮在高速深磨中的切削稳定性。此外,在高速深磨时,砂轮线速度的强化了磨削区附近的气障,从而影响到磨削液的有效注入,使磨削温度升高,进而影响磨削环境和加工质量。
本课题针对以上问题,重点研究了工程陶瓷等硬脆难加工材料高速深磨所必需的三项关键技术,即金属结合剂金刚石砂轮的整形技术、在线电解修锐(ELID)技术和磨削液注入技术,所取得的成果总结如下:
1)针对较粗粒度的金属结合剂金刚石砂轮无法单纯依靠电火花整形来实现整形的问题,本文提出了砂轮电火花—机械复合整形法。先利用电火花整形法去除砂轮偏心部分的金属结合剂,降低其对砂轮磨粒的把持强度:再以机械整形法去除偏心部分突出的磨粒。如此交替采用电火花与碳化硅滚轮对砂轮进行整形,直至砂轮达到整形精度要求为止。以此方法对100/120#青铜结合剂金刚石砂轮进行整形试验,试验结果表明它能够有效地解决较粗粒度金属结合剂砂轮的整形效率低的问题,整形精度可提高到6μm左右。
2)为改善ELID预修锐阶段的效率问题,本文增加了机械预修锐环节,以及时去除电解预修锐在砂轮表面所形成的氧化膜,恢复电解能力,从而使砂轮磨粒的突出高度尽快达到最佳切削高度。此外,本文还以砂轮磨粒突出高度保持不变为控制条件,建立了ELID稳定磨削阶段的控制模型,从而解决了工程陶瓷高速深磨ELID磨削时砂轮表面很难形成致密连续氧化膜而引起磨削过程不稳定的难题。
3)针对工程陶瓷高速深磨ELID磨削时ELID效率低下的问题,本文开发了封闭式电解阴极,并以此为核心构建了高速深磨ELID磨削试验平台,包括磨床、砂轮、电解装置、电源等部分;还对电解液的成膜性能进行了研究,开发出适用于青铜结合剂砂轮的ELID专用电解液。封闭式阴极与传统式阴极电解预修锐对比试验表明采用封闭式电解阴极可获得较高的电解电流,尤其是在砂轮线速度为150m/s时分别采用两阴极的电流差值可达1.1A,这充分表明了封闭式电解阴极在高速超高速磨削中的作用效果。
4)对氧化锆陶瓷分别进行高速深磨ELID与非ELID高速深磨工艺试验,试验结果表明ELID技术的应用增加了砂轮表面的有效磨刃密度,改善了砂轮的切削状态,从而使磨削力减小到3/4,表面粗糙度值减小0.15μm左右。
5)本文还提出一种新的磨削液注入方式,依此方式设计出了一种新型喷嘴——封闭式Y型喷嘴,并通过高速深磨试验验证了喷嘴的作用效果。试验结果表明:相对于普通L型喷嘴,采用封闭式Y型喷嘴供液能使工件得到更好的冷却,从而增加了工件材料磨除率;它还能及时清洗砂轮,使其处于良好的切削状态,有效地改善工件表面的加工质量。
Advanced engineering ceramics have been extensively used as structural materials in modern manufacturing industries due to their excellent properties,such as high hardness at both ambient and elevated temperatures,low thermal expansion, and excellent wear resistance and chemical inertness.Nevertheless,the high hardness and brittleness also make the machining of the ceramics very difficult.As a result,the machining process is associated with a high cost.Grinding is a commonly used machining process for engineering ceramics.Therefore,the improvement of efficiency in ceramics grinding shall greatly reduce the total machining cost.
In the past decades,a great attention has been paid to the development of high speed grinding technologies.In a high speed grinding process,the increase in grinding wheel velocity can significantly reduce the undeformed chip thickness per grit,and thus decrease the grinding force.This enables the improvement of ground surface quality and the elevation of material removal rate.High speed deep grinding (HSDG) is a process which integrated with high grinding velocity and large depth of cut in order to achieve high material removal rate while maintaining a high surface quality.
The HSDG of ceramics is often accompanied with large grinding force and high grinding temperature.The deterioration of machining conditions thus accelerates the wear of the grinding wheel.Therefore,the active abrasives quickly lose their cutting abilities,and the machining quality is deteriorated.It is thus important to keep active abrasives in good cutting condition throughout the HSDG grinding process.Previous investigations have shown that electrolytic in-process dressing(ELID) is a good approach for continuously maintain the grit sharpness during grinding.However, this technique was mainly used for dressing the fine abrasive wheels.Several technical issues need to be resolved if the ELID technology is applied to a HSDG process for engineering ceramics.The key issue is how to maintain the ELID efficiency during a HSDG process.In a HSDG process,the increasing wheel velocity strengthens the air barrier around the grinding wheel,which affects the impinging of grinding fluid,thus results in low ELID efficiency and high grinding temperature.
This project focused on the developments of key technologies for the HSDG of engineering ceramics,which tackled the key issues mentioned earlier.The technologies included the truing and ELID dressing for metal-bond diamond wheels, and the coolant supply technology.The significant results achieved are summarized below.
1) It is challenging to true metal-bond diamond wheels with coarse abrasives directly using the electrical discharge truing(EDT).In this project,the electrical discharge/mechanical hybrid truing method was developed.In this new truing method,the bond material on the wheel surface was firstly removed by EDT, which also lowered the holding strength of the grits.The protruded abrasive grits was then abraded by mechanical removal.EDT and mechanical truing were carried out alternately until the wheel may meet the grinding requirements.Using this method,the coarser abrasive metal bonded wheels were efficiently trued,with a roundness error of smaller than 6μm.
2) Mechanical pre-dressing was introduced into the ELID pre-dressing process. Using this approach,the oxide layer formed on the wheel surface was removed,and the electrical current during ELID pre-dressing was enhanced.This has significantly increased the pre-dressing efficiency.Additionally,a control model was also established,which effectively controlled the balance of metal bonded removal and wear of grinding wheel,and maintained the protrusion height of grits as a constant.
3) A new electrolysis cathode was successfully developed and used as a core component in the HSDG-ELID system.The application of such a cathode has solved a long-standing problem,which is the low ELID efficiency at relatively high grinding speeds.The comparison between the closed and the conventional cathodes demonstrated that a much higher pre-dressing current,hence an improved ELID efficiency was obtained.In addition,a new electrolytic fluid specifically for dressing bronze-bond diamond wheels was developed,which enhanced the ELID efficiency as well.The comparison between the HSDG processes with and without ELID showed that ELID technology increased the number of effective cutting grits on the wheel surface and improved their cutting abilities,resulting in a decreased grinding force and improved surface roughness.
4) A new coolant supply method was developed.This was accompanied with the design and fabrication of a closed Y-type nozzle.The HSDG experiments using the Y-type nozzle and the conventional L-type nozzle indicated that the closed Y-type nozzle improved the cooling conditions in the grinding zone,which enabled a higher materials removal rate.Additionally,the use of the new nozzle could better clean the wheel.This helped to maintain the wheel in a stable cutting condition and thus improve the quality of grinding.
引文
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