【摘要】：金剛石是自然界中已知最硬的材料,具有強(qiáng)度高、耐磨性好和優(yōu)異的物理化學(xué)性能,用金剛石作為切削材料制成的電鍍金剛石工具性能優(yōu)異,在光學(xué)玻璃、半導(dǎo)體、玉器、石材和硬脆難加工材料等方面性能尤為突出,被廣泛應(yīng)用于航空、航天、汽車、電子、陶瓷、建筑等領(lǐng)域,對(duì)工業(yè)的發(fā)展起著巨大的推動(dòng)作用。隨著電鍍金剛石工具的應(yīng)用,對(duì)其制造精度要求越來越高,國內(nèi)在制造高精度電鍍金剛石工具方面研究起步比較晚,對(duì)基礎(chǔ)機(jī)理研究不夠,精密復(fù)雜形面金剛石工具在制造精度和使用壽命方面存在著問題迫切需要解決,因此,開展對(duì)精密復(fù)雜形面電鍍金剛石工具制造方法和制造工藝的研究對(duì)于提高高精度復(fù)雜形面電鍍金剛石工具的制造水平,推動(dòng)我國航空航天、汽車制造和磨削加工等相關(guān)領(lǐng)域的發(fā)展具有重要意義。本文對(duì)精密金剛石工具制造原理和各種制造方法進(jìn)行了系統(tǒng)分析,設(shè)計(jì)了采用內(nèi)鍍法制造精密金剛石工具;并對(duì)內(nèi)電鍍法制造精度復(fù)雜形面金剛石工具主要工藝流程和精密上砂、鍍層機(jī)械性能、鍍層精度控制關(guān)鍵技術(shù)開展研究,以獲得制造精密復(fù)雜形面金剛石工具的科學(xué)制造方法和工藝。具體研究工作如下:1.高精度金剛石工具的制造方法研究。通過對(duì)內(nèi)鍍法、外鍍法和粉末冶金法制造金剛石工具的基本原理、工藝特點(diǎn)和應(yīng)用場(chǎng)合進(jìn)行系統(tǒng)分析,確定采用制造精度最高、形面復(fù)雜程度最大的內(nèi)鍍法來制造金剛石工具,并研究了內(nèi)鍍法制造精密金剛石工具的主要工藝流程和特點(diǎn)。2.內(nèi)電鍍法制造精密復(fù)雜形面金剛石工具的關(guān)鍵技術(shù)研究(1)內(nèi)電鍍精密上砂技術(shù)研究。通過對(duì)不同上砂方法對(duì)比分析,確定采用埋砂法來制造金剛石工具,并試驗(yàn)研究了陰極電流密度和上砂時(shí)間對(duì)上砂的影響規(guī)律。研究得到:以50/60粒度金剛石為例,陰極電流密度為0.5A/dm2,上砂時(shí)間為3小時(shí),上砂較好。(2)鍍液成分對(duì)鍍層機(jī)械性能影響研究。利用正交試驗(yàn)的方法對(duì)鍍液成分進(jìn)行優(yōu)化,分析鍍液各成分對(duì)鍍層性能的影響規(guī)律,采用極差法對(duì)試驗(yàn)結(jié)果進(jìn)行處理得到:鍍液成分中硫酸鎳含量270g/L,硫酸鈷20 g/L,氯化鈉10g/L,硼酸(30g/L)時(shí),鍍層機(jī)械性能最好。(3)鍍層內(nèi)應(yīng)力對(duì)金剛石工具精度影響研究。通過理論分析鍍層內(nèi)應(yīng)力的產(chǎn)生機(jī)理和影響因素,并通過試驗(yàn)研究了主要影響因素對(duì)鍍層精度的影響規(guī)律。研究結(jié)果表明:內(nèi)應(yīng)力隨著電流密度的增大呈上升趨勢(shì);鍍液中硫酸鈷的含量在10g/L、鍍液溫度為50℃、添加劑糖精含量為1g/L時(shí)鍍層內(nèi)應(yīng)力較小。3.項(xiàng)目制造的精密金剛石工具及精度。采用項(xiàng)目設(shè)計(jì)的內(nèi)電鍍制造方法制造金剛石工具,其精度測(cè)量得到:齒距誤差±0.003mm;圓弧半徑誤差±0.01mm;工作型面輪廓誤差0.005mm;徑向尺寸誤差±0.003mm;角度誤差±5′;形狀誤差0.006mm;跳動(dòng)誤差0.004mm。
[Abstract]:Diamond is the hardest material known in nature, with high strength, good wear resistance and excellent physical and chemical properties. Electroplating diamond tools made of diamond as cutting material have excellent performance in optical glass, semiconductor, jade, etc. Stone and hard-brittle refractory materials are widely used in the fields of aviation, aerospace, automobile, electronics, ceramics, architecture and so on, which play a great role in promoting the development of industry. With the application of electroplated diamond tools, the manufacturing accuracy of electroplated diamond tools is becoming more and more high. There are some problems in manufacturing precision and service life of precision diamond tools with complex surface, which need to be solved urgently. The research on the manufacturing methods and manufacturing technology of precision and complex diamond electroplating tools can improve the manufacturing level of high precision and complex surface electroplating diamond tools and promote China's aerospace industry. The development of automobile manufacturing and grinding processing is of great significance. In this paper, the manufacturing principle and various manufacturing methods of precision diamond tools are systematically analyzed, and the precision diamond tools made by internal plating are designed. The main technological process and key technologies of precision sanding, coating mechanical properties and coating precision control are also studied. In order to obtain the scientific manufacturing method and technology of precision and complex diamond tools. The specific research work is as follows: 1. Research on Manufacturing method of High Precision Diamond tools. Based on the systematic analysis of the basic principle, technological characteristics and application situation of diamond tools made by internal plating, external plating and powder metallurgy, it is determined that the inner plating method with the highest manufacturing precision and the most complex profile is used to manufacture diamond tools. The main technological process and characteristics of precision diamond tools made by internal plating were also studied. 2. Research on the key Technology of making Precision complex Surface Diamond tools by Internal Electroplating (1) Research on Precision Sand filling in Internal Electroplating. Based on the comparative analysis of different sand feeding methods, it is determined that the sand burying method is used to make diamond tools, and the effect of cathode current density and sand loading time on sand surfacing is studied experimentally. The results show that: (2) the effect of bath composition on the mechanical properties of the coating is studied by taking 50 / 60 grain size diamond as an example, the cathodic current density is 0.5A / dm ~ (2), and the time of sanding is 3 hours. (2) the effect of bath composition on the mechanical properties of the coating is studied. The composition of the plating solution was optimized by orthogonal test, and the influence of the composition of the bath on the coating performance was analyzed. The results were obtained by using the range method: the nickel sulfate content in the bath composition was 270 g / L, and the cobalt sulfate content was 20 g / L, and the results were as follows: cobalt sulfate 20 g / L, nickel sulfate 270 g / L and cobalt sulfate 20 g / L, respectively. When sodium chloride is 10 g / L, boric acid (30g/L), the mechanical properties of the coating are the best. (3) the effect of internal stress on the precision of diamond tools is studied. The mechanism and influencing factors of the internal stress of the coating are analyzed theoretically, and the influence law of the main influencing factors on the precision of the coating is studied through experiments. The results show that the internal stress increases with the increase of current density, and the internal stress of the coating is smaller when the content of cobalt sulfate is 10 g / L, the bath temperature is 50 鈩，

本文編號(hào)：2301587