【摘要】：超高速磨削指的是砂輪線速度在150m/s以上的磨削加工技術(shù)，由于其加工效率高、加工表面質(zhì)量好以及可加工超硬材料等優(yōu)勢，近年來取得了快速的發(fā)展。伴隨著磨削過程產(chǎn)生的大量磨削熱易造成工件燒傷，為提高表面質(zhì)量，通常采用高壓冷卻液方式向磨削區(qū)供液，這種冷卻方法效率低、成本高且對環(huán)境污染大，由于超高速磨削時的氣流屏障，真正進入磨削區(qū)域的磨削液比例低，冷卻效果差。此外，由于窄深槽固有的結(jié)構(gòu)特性以及磨削液的粘滯性，使其難以對磨削區(qū)進行充分冷卻。因此，需要設(shè)計適用于窄深槽磨削的新型高效冷卻方式。 新型CBN具有很好的熱傳導(dǎo)性能，可有效降低傳入工件的磨削熱，進而使得工件表面的溫度大幅下降。為研究開發(fā)適用于單層CBN砂輪高效深磨的新型冷卻方式提供了基礎(chǔ)。 本文結(jié)合傳統(tǒng)干磨削的理念，提出適用于超高速磨削尤其是高效深磨的砂輪風(fēng)冷結(jié)構(gòu)設(shè)計方案，并對設(shè)計結(jié)果進行了流場分析。主要的研究內(nèi)容包括： （1）基于傳統(tǒng)磨削時對砂輪氣流屏障研究的方法，對窄深槽磨削時砂輪周圍的氣流分布情況進行了仿真分析，分析得出砂輪厚度、砂輪線速度、砂輪直徑、砂輪表面粗糙度以及窄深槽尺寸等5個因素對氣流場分布的影響，同時闡述了高效深磨時移動熱源建立的原則，，為后續(xù)多場耦合驗證風(fēng)冷式砂輪結(jié)構(gòu)的冷卻效果和優(yōu)化設(shè)計奠定了理論基礎(chǔ)。 （2）根據(jù)外置噴嘴冷卻方式進行冷卻時各個參數(shù)對磨削冷卻效果的影響，提出了適用于內(nèi)風(fēng)冷砂輪出風(fēng)口設(shè)計的理論，即以工件表面換熱能力最大為目標(biāo)確定砂輪基體和卡盤上出風(fēng)口的尺寸，根據(jù)空氣動力學(xué)基本理論確定弧道形式。在流量確定的情況下以最大壓升為目標(biāo)函數(shù)設(shè)計卡盤上的渦扇葉片結(jié)構(gòu)用來產(chǎn)生高速氣流。 （3）在流場分析軟件中，完成對風(fēng)冷式砂輪結(jié)構(gòu)的環(huán)境建模，分析其冷卻效果，并對風(fēng)冷式砂輪結(jié)構(gòu)的渦扇葉片結(jié)構(gòu)和出風(fēng)口結(jié)構(gòu)分別進行流場分析，為下一步分區(qū)域的優(yōu)化設(shè)計提供參考。
[Abstract]:Ultra-high speed grinding refers to grinding technology with linear speed of grinding wheel above 150m/s. Because of its high machining efficiency, good surface quality and machinability of superhard materials, it has made rapid development in recent years. In order to improve the surface quality, high pressure coolant is usually used to feed the grinding area with a large amount of grinding heat produced by grinding process. This cooling method is of low efficiency, high cost and high pollution to the environment. Because of the airflow barrier in super high speed grinding, the ratio of grinding fluid entering grinding area is low and the cooling effect is poor. In addition, due to the inherent structural characteristics of narrow deep groove and viscosity of grinding fluid, it is difficult to fully cool the grinding area. Therefore, it is necessary to design a new high efficiency cooling method suitable for narrow deep groove grinding. The new CBN has good heat conduction performance, which can effectively reduce the grinding heat of the imported workpiece, and make the surface temperature of the workpiece drop significantly. It provides the foundation for the research and development of a new cooling method suitable for high efficiency deep grinding of single layer CBN grinding wheel. Based on the idea of traditional dry grinding, this paper puts forward a design scheme of air-cooled structure for super high speed grinding, especially for high efficiency deep grinding, and analyzes the flow field of the design results. The main research contents are as follows: (1) based on the traditional method to study the airflow barrier of grinding wheel, the distribution of air flow around the grinding wheel during narrow and deep groove grinding is simulated and analyzed, and the thickness of grinding wheel and the linear velocity of grinding wheel are obtained. The influence of five factors, such as the diameter of grinding wheel, the surface roughness of grinding wheel and the size of narrow deep groove, on the distribution of air flow field is discussed, and the principle of establishing moving heat source during high efficiency deep grinding is expounded. It lays a theoretical foundation for the subsequent multi-field coupling verification of cooling effect and optimization design of air-cooled grinding wheel structure. (2) the influence of various parameters on grinding cooling effect according to the cooling mode of external nozzle. A theory suitable for the design of the air outlet of the inner air-cooled grinding wheel is put forward, that is, the size of the air outlet on the wheel matrix and chuck is determined with the aim of maximum heat transfer capacity on the surface of the workpiece, and the form of the arc channel is determined according to the basic theory of aerodynamics. With the maximum pressure rise as the objective function, the vortex blade structure on the chuck is designed to produce high speed airflow. (3) in the flow field analysis software, the environmental modeling of the air-cooled grinding wheel structure is completed. The cooling effect is analyzed, and the flow field of the blade structure and the outlet structure of the air-cooled grinding wheel are analyzed respectively, which provides a reference for the optimization design of the next sub-region.
【學(xué)位授予單位】：太原理工大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2015
【分類號】：TG580.6

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