【摘要】：藍(lán)寶石具有機(jī)械強(qiáng)度高、導(dǎo)熱率好、耐化學(xué)腐蝕及光通波段范圍寬等優(yōu)點(diǎn),因而被廣泛用作高馬赫導(dǎo)彈及高速飛行器的整流罩材料。但目前的藍(lán)寶石整流罩研磨加工存在效率低,易產(chǎn)生裂紋、劃痕和崩邊等表面缺陷,這嚴(yán)重制約了藍(lán)寶石整流罩的應(yīng)用。磁控研磨加工技術(shù)具有適應(yīng)性強(qiáng)、精度高和加工表面質(zhì)量好等優(yōu)點(diǎn),可將其應(yīng)用于藍(lán)寶石整流罩的研磨加工。本文通過化學(xué)復(fù)合鍍法制備出金剛石相對(duì)含量較高的磁性磨料,對(duì)藍(lán)寶石整流罩磁控研磨加工實(shí)驗(yàn)進(jìn)行研究,系統(tǒng)分析了主要工藝參數(shù)對(duì)材料去除率和表面粗糙度的影響,探討了整流罩磁控研磨加工前后的球度誤差和表面質(zhì)量。論文的主要工作與成果如下:(1)開展了化學(xué)復(fù)合鍍制備磁性磨料過程中金剛石顆粒的吸附與沉積機(jī)理研究,建立了相應(yīng)的理論模型,分析了鍍液溫度、鍍液中懸浮的金剛石顆粒濃度、金剛石顆粒的粒徑大小以及基體粉末的形狀和粒徑大小對(duì)磁性磨料鍍層中金剛石相對(duì)含量的影響規(guī)律;進(jìn)行了化學(xué)復(fù)合鍍實(shí)驗(yàn),研究了鍍液金剛石濃度及金剛石粒徑大小對(duì)鍍層中金剛石相對(duì)含量的影響規(guī)律。(2)對(duì)藍(lán)寶石整流罩磁控研磨工具進(jìn)行了總體結(jié)構(gòu)設(shè)計(jì),建立了研磨工具的二維靜態(tài)磁場(chǎng)有限元模型,仿真分析了磁極厚度、磁極頭表面開槽數(shù)量、開槽寬度和槽間角度對(duì)加工間隙磁場(chǎng)強(qiáng)度及其梯度的影響;利用仿真結(jié)果優(yōu)化改進(jìn)了磁控研磨工具的結(jié)構(gòu)并研制了藍(lán)寶石整流罩磁控研磨工具。(3)進(jìn)行了藍(lán)寶石整流罩磁控研磨加工實(shí)驗(yàn),研究了研磨罩板厚度、主軸轉(zhuǎn)速、乙二胺濃度以及研磨時(shí)間對(duì)材料去除率及表面粗糙度的影響;綜合考慮藍(lán)寶石整流罩的材料去除率和表面粗糙度,得到藍(lán)寶石整流罩磁控研磨加工最佳工藝參數(shù)組合,在該組合下材料去除率為142μm3/min,表面粗糙度為93nm,整流罩表面的球度誤差由初始的54.54μm降低到11.64μm,且其表面質(zhì)量顯著提高。
[Abstract]:Sapphire has the advantages of high mechanical strength, good thermal conductivity, chemical corrosion resistance and wide optical band, so it is widely used as a fairing material for high Mach missiles and high speed aircraft. However, there are some surface defects in sapphire fairing, such as low efficiency, easy to produce cracks, scratches and flanging, which seriously restrict the application of sapphire fairing. Magnetic controlled grinding technology has the advantages of high adaptability, high precision and good surface quality, so it can be applied to the grinding of sapphire fairing. In this paper, the magnetic abrasive with relatively high diamond content was prepared by electroless composite plating. The experiment of magnetic controlled grinding of sapphire fairing was studied, and the influence of main process parameters on material removal rate and surface roughness was analyzed systematically. The sphericity error and surface quality of the fairing before and after magnetic controlled grinding are discussed. The main work and achievements are as follows: (1) the adsorption and deposition mechanism of diamond particles in the preparation of magnetic abrasive by electroless composite plating has been studied, the corresponding theoretical model has been established, and the bath temperature has been analyzed. The effect of the concentration of diamond particles suspended in bath, the size of diamond particles and the shape and size of matrix powder on the relative content of diamond in magnetic abrasive coating were studied. The effect of diamond concentration in bath and diamond particle size on the relative content of diamond in the coating was studied. (2) the overall structure of the magnetic controlled grinding tool for sapphire fairing was designed. A two-dimensional static magnetic field finite element model of grinding tool is established. The effects of the thickness of magnetic pole, the number of slots on the surface of magnetic pole head, the width of slot and the angle between slots on the magnetic field intensity and gradient of machining gap are simulated and analyzed. The structure of the magnetic controlled grinding tool is optimized by using the simulation results and the magnetic controlled grinding tool for the sapphire fairing is developed. (3) the experiment of the sapphire fairing magnetically controlled grinding is carried out, and the thickness of the abrasive cover plate and the rotation speed of the spindle are studied. The effects of ethylenediamine concentration and grinding time on the removal rate and surface roughness of the sapphire fairing were studied, and the optimum processing parameters were obtained by considering the material removal rate and the surface roughness of the sapphire fairing. The material removal rate is 142 渭 m 3 / min, the surface roughness is 93 nm, the sphericity error of the fairing surface is reduced from 54.54 渭 m to 11.64 渭 m, and the surface quality is improved significantly.
【學(xué)位授予單位】：南京航空航天大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類號(hào)】：TG580.68

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