超聲ELID復(fù)合內(nèi)圓磨削ZTA納米復(fù)相陶瓷的磨削機理
發(fā)布時間：2019-05-18 00:28
【摘要】：納米復(fù)相陶瓷以其優(yōu)異的力學(xué)性能、穩(wěn)定的化學(xué)性能和較低的微缺陷敏感性,正成為國民經(jīng)濟和尖端科技領(lǐng)域的一類關(guān)鍵性材料。不過,納米復(fù)相陶瓷的應(yīng)用需要很高的形狀尺寸精度和表面完整性,其加工仍然較困難,突出表現(xiàn)為難以同時實現(xiàn)高精度、高效率和高可靠性加工。本文將以精密高效為主要特征的超聲振動技術(shù)和以超精密鏡面為主要特征的ELID(在線電解修銳)磨削技術(shù)相復(fù)合,以ZTA納米復(fù)相陶瓷為載體,研究超聲振動參數(shù)、磨削參數(shù)與ELID參數(shù)之間的關(guān)系及其對磨削過程的影響,以及超聲ELID磨削工藝參數(shù)對工件表面紋理的影響關(guān)系,以揭示超聲ELID磨削納米復(fù)相陶瓷的磨削機理,為進一步完善硬脆材料高效鏡面加工理論和技術(shù)提供支撐。首先搭建超聲ELID復(fù)合磨削ZTA納米陶瓷試驗研究平臺。主要工作包括:基于波動理論和ANSYS有限元模態(tài)分析方法設(shè)計超聲振動系統(tǒng);分別設(shè)計電解裝置的陽極和陰極,然后將它們集成為ELID裝置;根據(jù)電火花加工原理,并通過調(diào)節(jié)整形各階段的參數(shù),對鑄鐵結(jié)合劑金剛石砂輪進行整形試驗,使砂輪的初始圓度誤差由32μm降低到約2μm,大多數(shù)磨粒凸出鑄鐵結(jié)合劑表面,從而達到砂輪精度要求。然后根據(jù)超聲ELID復(fù)合內(nèi)圓磨削砂輪氧化膜生長和去除的電化學(xué)原理,并考慮軸向超聲振動輔助磨削幾何參數(shù)等因素,建立任意時間超聲ELID復(fù)合磨削砂輪氧化膜厚度預(yù)測模型。對該模型進行仿真分析的結(jié)果表明:在氧化膜厚度近似線性增長階段,極間間隙越大,則氧化膜形成厚度越小,形成速度越慢;磨粒體積比越大,則氧化膜形成厚度越大,形成速度越快;占空比越大,則氧化膜形成厚度越大,形成速度越快。在氧化膜厚度呈非線性增長階段,超聲頻率越高,則成膜速度越快,平衡時形成的氧化膜厚度越大。接著開展單因素試驗,歸納出電源電壓、脈沖寬度與脈沖間隔、極間間隙、砂輪轉(zhuǎn)速及超聲振動對超聲ELID復(fù)合磨削預(yù)修銳階段氧化膜的厚度、形成速率、表面形貌的影響機理;通過改變砂輪轉(zhuǎn)速、工件轉(zhuǎn)速、磨削深度、砂輪粒度,定性分析動態(tài)磨削過程中各參數(shù)對氧化膜狀態(tài)的影響;進行停電光磨試驗和停電光磨附加超聲振動試驗,揭示超聲振動對氧化膜拋光性的影響機理。為驗證砂輪氧化膜厚度模型,采集砂輪預(yù)修銳和動態(tài)磨削過程中測量點的厚度值,同時理論計算測量點的參數(shù)值,結(jié)果表明,玻爾茲曼函數(shù)擬合的相關(guān)度較好,厚度測量值趨勢與理論預(yù)測值趨勢相仿,這反映氧化膜厚度隨時間而不斷增長,增長速度隨時間而變緩,從而證實氧化膜厚度模型的合理性。其次在超聲ELID復(fù)合磨削磨粒運動學(xué)分析和動態(tài)有效磨粒數(shù)模型構(gòu)建的基礎(chǔ)上,建立超聲ELID復(fù)合磨削平均未變形磨屑厚度模型。接著開展超聲ELID磨削ZTA納米陶瓷材料去除特性試驗,通過研究磨削深度與磨削力、工件表面粗糙度及表面形貌的變化關(guān)系,將磨削深度與磨削結(jié)果之間的關(guān)系轉(zhuǎn)變?yōu)槲醋冃文バ己穸扰c磨削結(jié)果之間的關(guān)系。通過分析不同未變形磨屑厚度條件下磨削力和表面粗糙度的變化規(guī)律以及工件表面SEM(掃描電子顯微鏡)照片,確定ZTA納米陶瓷材料去除的脆塑性轉(zhuǎn)變條件為平均未變形磨屑厚度1.565μm。然后基于未變形磨屑厚度模型建立表面粗糙度模型,通過模型仿真和表面粗糙度試驗證實表面粗糙度模型的正確性,繼而證實未變形磨屑厚度模型及ZTA納米陶瓷材料去除的脆塑性轉(zhuǎn)變臨界條件。最后通過磨粒切削軌跡分析和試驗揭示超聲ELID復(fù)合磨削表面創(chuàng)成機理。本文研究證實超聲ELID復(fù)合磨削砂輪氧化膜厚度預(yù)測模型的合理性,為揭示超聲ELID磨削納米復(fù)相陶瓷的磨削過程奠定了一定的理論基礎(chǔ);超聲ELID磨削ZTA納米陶瓷材料去除的脆塑性轉(zhuǎn)變臨界切深的確立,為進一步改善納米復(fù)相陶瓷表面質(zhì)量提供了一定依據(jù)。
[Abstract]:The nano-phase ceramics, with its excellent mechanical properties, stable chemical properties and low sensitivity to micro-defects, are becoming a key material in the national economy and the advanced science and technology field. However, the application of nano-phase ceramics requires high dimensional accuracy and surface integrity, and the processing is still difficult, and it is difficult to achieve high precision, high efficiency and high reliability at the same time. In this paper, the ultrasonic vibration technology with high precision and high efficiency and the ELID (on-line electrolytic dressing) grinding technology with ultra-precision mirror as the main feature are combined, and the ultrasonic vibration parameters are studied by using the ZTA nano-phase ceramics as the carrier. The relationship between the grinding parameters and the ELID parameters and its influence on the grinding process, and the influence of the ultrasonic ELID grinding process parameters on the surface texture of the workpiece to reveal the grinding mechanism of the ultrasonic ELID grinding nano-phase ceramics, In ord to further improve that high-efficiency mirror processing theory and technology of the hard and brittle material. First, an ultrasonic ELID composite grinding ZTA nano-ceramic test research platform was set up. The main work comprises the following steps of: designing an ultrasonic vibration system based on the fluctuation theory and the ANSYS finite element mode analysis method; respectively designing the anode and the cathode of the electrolysis device, and then integrating the anode and the cathode of the electrolysis device into an ELID device; and adjusting the parameters of each stage by adjusting the parameters of each stage according to the electric spark machining principle, The diamond grinding wheel of the cast iron bonding agent is subjected to the shaping test, the initial roundness error of the grinding wheel is reduced from 32. m u.m to about 2. m u.m, and most of the abrasive grains project on the surface of the cast iron bonding agent, so that the accuracy requirement of the grinding wheel is achieved. Then, according to the electrochemical principle of the ultrasonic ELID composite inner circle grinding wheel oxidation film growth and removal, and considering the factors such as the axial ultrasonic vibration auxiliary grinding geometric parameters, an arbitrary time ultrasonic ELID composite grinding wheel oxide film thickness prediction model is established. The results of the simulation analysis of the model show that the larger the gap between the electrodes when the thickness of the oxide film is approximately the linear growth phase, the smaller the thickness of the oxide film, the slower the formation speed, and the larger the volume ratio of the abrasive grains, the larger the thickness of the oxide film, the faster the formation speed, and the larger the duty ratio, The larger the thickness of the oxide film, the faster the formation speed. In that non-linear growth phase of the oxide film thickness, the higher the ultrasonic frequency, the faster the film formation speed and the greater the thickness of the oxide film formed at the time of equilibrium. then a single factor test is carried out to sum up the influence mechanism of the power supply voltage, the pulse width and the pulse interval, the interelectrode gap, the grinding wheel speed and the ultrasonic vibration on the thickness, the forming rate and the surface appearance of the ultrasonic ELID composite grinding pre-repairing stage oxidation film; and by changing the rotating speed of the grinding wheel, The influence of the parameters on the state of the oxide film during the dynamic grinding of the workpiece, the depth of the grinding, the particle size of the grinding wheel and the qualitative analysis of the dynamic grinding of the workpiece were carried out, and the influence of the ultrasonic vibration on the polishing of the oxide film was revealed. In order to verify the thickness model of the oxidation film of the grinding wheel, the thickness of the measuring points in the pre-sharpening and dynamic grinding of the grinding wheel is collected, and the parameter value of the measuring point is calculated by the theory. The results show that the correlation between the fitting of the Boltzmann function is good, and the trend of the thickness measurement is similar to that of the theoretical prediction value. This reflects the increase of the thickness of the oxide film over time, and the growth rate is slow with time, thus confirming the rationality of the thickness model of the oxide film. Secondly, on the basis of the analysis of the kinematic and dynamic effective abrasive particle number model of the ultrasonic ELID composite grinding, the model of the average undeformed chip thickness of the ultrasonic ELID composite grinding was established. The relationship between the grinding depth and the grinding force, the surface roughness of the workpiece and the surface morphology was studied. The relationship between the grinding depth and the grinding result was changed to the relationship between the thickness of the undeformed chip and the result of the grinding. The change law of the grinding force and the surface roughness and the SEM (scanning electron microscope) photograph of the surface of the workpiece were analyzed by analyzing the change of the grinding force and the surface roughness. The brittle-plastic transition condition of the removal of the ZTA nano-ceramic material is determined to be the average undeformed abrasive chip thickness of 1.565. m u.m. The surface roughness model is then established on the basis of the non-deformed chip thickness model, and the correctness of the surface roughness model is confirmed by the model simulation and the surface roughness test. In turn, the critical condition of the brittle-plastic transition of the undeformed chip thickness model and the removal of the ZTA nano-ceramic material is confirmed. Finally, the formation mechanism of the ultrasonic ELID composite grinding surface is revealed by the analysis and test of the abrasive cutting trajectory. The rationality of the ultrasonic ELID composite grinding wheel oxide film thickness prediction model is studied in this paper, which lays a theoretical basis for revealing the grinding process of the ultrasonic ELID grinding nano-phase ceramics. The critical cutting depth of the brittle-plastic transition of the ultrasonic ELID grinding ZTA nano-ceramic material is established. In ord to further improve that surface quality of the nano-phase ceramic, a certain basis is provided.
【學(xué)位授予單位】：河南理工大學(xué)
【學(xué)位級別】：博士
【學(xué)位授予年份】：2015
【分類號】：TQ174.6
本文編號：2479519
[Abstract]:The nano-phase ceramics, with its excellent mechanical properties, stable chemical properties and low sensitivity to micro-defects, are becoming a key material in the national economy and the advanced science and technology field. However, the application of nano-phase ceramics requires high dimensional accuracy and surface integrity, and the processing is still difficult, and it is difficult to achieve high precision, high efficiency and high reliability at the same time. In this paper, the ultrasonic vibration technology with high precision and high efficiency and the ELID (on-line electrolytic dressing) grinding technology with ultra-precision mirror as the main feature are combined, and the ultrasonic vibration parameters are studied by using the ZTA nano-phase ceramics as the carrier. The relationship between the grinding parameters and the ELID parameters and its influence on the grinding process, and the influence of the ultrasonic ELID grinding process parameters on the surface texture of the workpiece to reveal the grinding mechanism of the ultrasonic ELID grinding nano-phase ceramics, In ord to further improve that high-efficiency mirror processing theory and technology of the hard and brittle material. First, an ultrasonic ELID composite grinding ZTA nano-ceramic test research platform was set up. The main work comprises the following steps of: designing an ultrasonic vibration system based on the fluctuation theory and the ANSYS finite element mode analysis method; respectively designing the anode and the cathode of the electrolysis device, and then integrating the anode and the cathode of the electrolysis device into an ELID device; and adjusting the parameters of each stage by adjusting the parameters of each stage according to the electric spark machining principle, The diamond grinding wheel of the cast iron bonding agent is subjected to the shaping test, the initial roundness error of the grinding wheel is reduced from 32. m u.m to about 2. m u.m, and most of the abrasive grains project on the surface of the cast iron bonding agent, so that the accuracy requirement of the grinding wheel is achieved. Then, according to the electrochemical principle of the ultrasonic ELID composite inner circle grinding wheel oxidation film growth and removal, and considering the factors such as the axial ultrasonic vibration auxiliary grinding geometric parameters, an arbitrary time ultrasonic ELID composite grinding wheel oxide film thickness prediction model is established. The results of the simulation analysis of the model show that the larger the gap between the electrodes when the thickness of the oxide film is approximately the linear growth phase, the smaller the thickness of the oxide film, the slower the formation speed, and the larger the volume ratio of the abrasive grains, the larger the thickness of the oxide film, the faster the formation speed, and the larger the duty ratio, The larger the thickness of the oxide film, the faster the formation speed. In that non-linear growth phase of the oxide film thickness, the higher the ultrasonic frequency, the faster the film formation speed and the greater the thickness of the oxide film formed at the time of equilibrium. then a single factor test is carried out to sum up the influence mechanism of the power supply voltage, the pulse width and the pulse interval, the interelectrode gap, the grinding wheel speed and the ultrasonic vibration on the thickness, the forming rate and the surface appearance of the ultrasonic ELID composite grinding pre-repairing stage oxidation film; and by changing the rotating speed of the grinding wheel, The influence of the parameters on the state of the oxide film during the dynamic grinding of the workpiece, the depth of the grinding, the particle size of the grinding wheel and the qualitative analysis of the dynamic grinding of the workpiece were carried out, and the influence of the ultrasonic vibration on the polishing of the oxide film was revealed. In order to verify the thickness model of the oxidation film of the grinding wheel, the thickness of the measuring points in the pre-sharpening and dynamic grinding of the grinding wheel is collected, and the parameter value of the measuring point is calculated by the theory. The results show that the correlation between the fitting of the Boltzmann function is good, and the trend of the thickness measurement is similar to that of the theoretical prediction value. This reflects the increase of the thickness of the oxide film over time, and the growth rate is slow with time, thus confirming the rationality of the thickness model of the oxide film. Secondly, on the basis of the analysis of the kinematic and dynamic effective abrasive particle number model of the ultrasonic ELID composite grinding, the model of the average undeformed chip thickness of the ultrasonic ELID composite grinding was established. The relationship between the grinding depth and the grinding force, the surface roughness of the workpiece and the surface morphology was studied. The relationship between the grinding depth and the grinding result was changed to the relationship between the thickness of the undeformed chip and the result of the grinding. The change law of the grinding force and the surface roughness and the SEM (scanning electron microscope) photograph of the surface of the workpiece were analyzed by analyzing the change of the grinding force and the surface roughness. The brittle-plastic transition condition of the removal of the ZTA nano-ceramic material is determined to be the average undeformed abrasive chip thickness of 1.565. m u.m. The surface roughness model is then established on the basis of the non-deformed chip thickness model, and the correctness of the surface roughness model is confirmed by the model simulation and the surface roughness test. In turn, the critical condition of the brittle-plastic transition of the undeformed chip thickness model and the removal of the ZTA nano-ceramic material is confirmed. Finally, the formation mechanism of the ultrasonic ELID composite grinding surface is revealed by the analysis and test of the abrasive cutting trajectory. The rationality of the ultrasonic ELID composite grinding wheel oxide film thickness prediction model is studied in this paper, which lays a theoretical basis for revealing the grinding process of the ultrasonic ELID grinding nano-phase ceramics. The critical cutting depth of the brittle-plastic transition of the ultrasonic ELID grinding ZTA nano-ceramic material is established. In ord to further improve that surface quality of the nano-phase ceramic, a certain basis is provided.
【學(xué)位授予單位】：河南理工大學(xué)
【學(xué)位級別】：博士
【學(xué)位授予年份】：2015
【分類號】：TQ174.6
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