【摘要】：在實(shí)際加工過(guò)程中,變截面細(xì)長(zhǎng)軸由于自身剛度的問(wèn)題容易產(chǎn)生徑向變形,但軸的加工精度往往要求很高,由于傳統(tǒng)電解加工方法很難達(dá)到其精度要求,因此并不能用常規(guī)的電解磨削方法對(duì)其進(jìn)行加工。對(duì)于變截面細(xì)長(zhǎng)軸容易變形的問(wèn)題已經(jīng)有了一種工藝方法——隨動(dòng)中極法電解磨削,在此基礎(chǔ)上本文設(shè)計(jì)了一種新的工藝方法“可變載荷隨動(dòng)中極法”電解磨削,并對(duì)變截面細(xì)長(zhǎng)軸的典型零件頂頭零件進(jìn)行加工分析。本文將從理論、力學(xué)模型、仿真以及試驗(yàn)驗(yàn)證幾個(gè)方面對(duì)其進(jìn)行分析研究。首先,簡(jiǎn)單概述和總結(jié)了電解加工技術(shù)的國(guó)內(nèi)外發(fā)展和應(yīng)用狀況,闡述了電解加工的基本原理和特點(diǎn),并系統(tǒng)分析了影響其加工精度的因素。針對(duì)上面提出的兩種加工工藝方法進(jìn)行理論上敘述,再對(duì)本文主要研究對(duì)象頂頭零件建立電解磨削力學(xué)模型并進(jìn)行力學(xué)分析。其次,借助ANSYSWorkbench仿真軟件,分別使用普通隨動(dòng)中極和可變載荷隨動(dòng)中極兩種加工工藝方法對(duì)零件的變形規(guī)律和應(yīng)力大小變化進(jìn)行分析,并對(duì)這兩種仿真的結(jié)果加以對(duì)比。結(jié)果表明,與隨動(dòng)中極法電解磨削相比,可變載荷隨動(dòng)中極法加工的零件剛度最小處徑向位移從最大的27.9um降到9.8um,最大應(yīng)力從25.4MPa降低到22.4MPa,極大地提高了加工精度。再利用瞬間動(dòng)力學(xué)模型對(duì)可變載荷所施加的力進(jìn)行了分析和選擇,得到在可變載荷的力與零件磨削力徑向分力差值在4N時(shí),可變載荷隨動(dòng)中極法電解磨削的加工精度最高。最后,考慮到在可變載荷隨動(dòng)中極法電解磨削中影響零件徑向變形的機(jī)械因素主要是零件轉(zhuǎn)速Vw、縱向進(jìn)給速度Vf和磨削深度ap,因此本文利用正交實(shí)驗(yàn)對(duì)這幾個(gè)因素的參數(shù)進(jìn)行優(yōu)化分析,最終得到零件轉(zhuǎn)速240 r/min,縱向進(jìn)給速度0.140 mm/r,磨削深度0.025 mm時(shí)可變載荷加工工藝能夠達(dá)到很高的加工精度。對(duì)于結(jié)果進(jìn)行了實(shí)驗(yàn)驗(yàn)證,最終得出方案是可行的。
[Abstract]:In the process of practical machining, variable cross-section slender shaft is easy to produce radial deformation due to its own stiffness, but the machining accuracy of shaft is often very high, because the traditional electrolytic machining method is difficult to achieve its precision requirements. Therefore, the conventional electrolytic grinding method can not be used to process it. For the problem of easy deformation of slender axis with variable cross section, there has been a new process method of electrolysis grinding, which is the following middle pole method. On the basis of this, a new process method, "variable load following middle pole method", has been designed for electrolytic grinding. And the machining analysis of typical parts with long axis with variable cross-section is carried out. In this paper, the theory, mechanical model, simulation and experimental verification will be analyzed and studied. Firstly, the development and application of ECM at home and abroad are briefly summarized, the basic principle and characteristics of ECM are expounded, and the factors affecting machining accuracy are analyzed systematically. In view of the above two machining technology methods are described theoretically, and then the mechanical model of electrolytic grinding is established and the mechanical analysis is carried out for the main research object of this paper. Secondly, with the help of ANSYSWorkbench simulation software, the deformation law and stress change of the parts are analyzed by using two processing methods of common middle pole following and variable load following middle pole, and the results of the two kinds of simulation are compared. The results show that the minimum radial displacement and the maximum stress are reduced from the maximum 27.9um to 9.8 ump and the maximum stress from 25.4MPa to 22.4 MPA, respectively, compared with the electrolysis grinding with the following middle pole method, and the minimum radial displacement of the parts machined by the variable load follower electrode method is reduced from the maximum 27.9um to 9.8 ump. The machining accuracy is greatly improved. Then the force applied by variable load is analyzed and selected by using instantaneous dynamic model. When the radial force difference between variable load and grinding force of parts is 4 N, the machining accuracy of electrolysis grinding with variable load is the highest when the radial force difference between variable load and grinding force is 4 N. Finally, considering that the main mechanical factors that affect the radial deformation of parts in variable load follower electrolysis grinding are parts rotational speed Vw, longitudinal feed speed Vf and grinding depth ap,. In this paper, the parameters of these factors are optimized and analyzed by orthogonal experiment. Finally, the rotational speed of parts is 240r / min and the longitudinal feed speed is 0.140 mm/r,. The variable load machining process with grinding depth of 0.025 mm can achieve high machining accuracy. The results are verified by experiments, and the scheme is feasible.
【學(xué)位授予單位】：西華大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2015
【分類號(hào)】：TG580;TG662

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