变曲率沟槽高精度球体精研工艺优化实验研究
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摘要
基于变曲率沟槽研磨抛光方法,对球体进行运动学分析并建立运动学方程。利用Matlab绘制球体表面加工轨迹并结合Preston方程建立球度误差计算模型。仿真结果表明最短的加工时间为26 h。基于田口法对精研阶段球体加工工艺进行正交试验,并对实验结果进行方差分析及S-N-K分析,优化各加工阶段加工参数以获得最优的圆度值。结果表明:在半精研阶段将球体的球度研磨至0.7μm,精研阶段研磨至0.3μm时加工效率最高。完成精研阶段(半精研、精研和超精研)阶段只需要29 h,相较于传统的加工方法其效率提高了14.7%,并且抛光结束后的氧化锆陶瓷球粗糙度达到14 nm,圆度达到0.13μm,达到了G5级国家标准。
The kinematics equation of the ball is established through theoretical analysis based on the variable-radius groove polishing method. The processing trajectory was plotted using Matlab, and the spherical error calculation model is established with the Preston equation. The result shows that the shortest processing time is 26 hours. The orthogonal test was done based on Taguchi method, then the analysis of variance(ANOVA) and Student-Newman-Keuls(S-N-K) posttest were utilized for the optimization of different stage processing parameters to obtain the highest roundness. The results can be concluded that the highest lapping efficiency can be achieved when the sphericity reach to 0.7 μm after semi-finishing, and 0.3 μm for finishing process. It takes only 29 hours including semi-finishing, finishing, ultra-finishing stages, comparing with the traditional method the efficiency improved 14.7%. Meanwhile the final roughness and sphericity of high precision Zirconia ceramic balls were 14 nm and 0.13 μm respectively, achieved the G5 grade of national standard.
The kinematics equation of the ball is established through theoretical analysis based on the variable-radius groove polishing method. The processing trajectory was plotted using Matlab, and the spherical error calculation model is established with the Preston equation. The result shows that the shortest processing time is 26 hours. The orthogonal test was done based on Taguchi method, then the analysis of variance(ANOVA) and Student-Newman-Keuls(S-N-K) posttest were utilized for the optimization of different stage processing parameters to obtain the highest roundness. The results can be concluded that the highest lapping efficiency can be achieved when the sphericity reach to 0.7 μm after semi-finishing, and 0.3 μm for finishing process. It takes only 29 hours including semi-finishing, finishing, ultra-finishing stages, comparing with the traditional method the efficiency improved 14.7%. Meanwhile the final roughness and sphericity of high precision Zirconia ceramic balls were 14 nm and 0.13 μm respectively, achieved the G5 grade of national standard.
引文
[1] 李庆忠,朱强,李东炬.基于接触应力的氮化硅混合陶瓷球轴承曲率半径优化设计[J].机械传动,2017(8):100-104.
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[12] LUO R,X L M,ZHA T J,et al.Modeling and simulation of surface roughness for spherical grinding[J].Journal of Shanghai Jiao Tong University,2013,47(5):709-714.
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[14] 何荣军,卢艳,王钧,等.基于AHP模糊评价法在草菇蛋卷研制中的应用[J].浙江工业大学学报,2015,43(1):73-76.
[15] 杨庆华,占伟涛,吴海伟,等.基于正交试验、BP神经网络和遗传算法的冷挤压模具优化设计方法[J].浙江工业大学学报,2015,43(3):251-256.
[16] 中华人民共和国国家质量监督检验检疫总局.中华人民共和国国家标准——滚动轴承陶瓷球:GB/T 308.2—2013[S].北京:中国标准出版社,2013:2-12.
[2] 吴玉厚,沈亚超,李颂华,等.氧化锆陶瓷磨削表面质量仿真与实验研究[J].机械与电子,2017,35(3):8-12.
[3] YUAN J L,LU B H,LIN X,et al.Research on abrasives in the chemical mechanical polishing process for silicon nitride balls[J].Journal of Xiamen University(natural science),2002,129(s1):171-175.
[4] TADZIJEVAS A,BARZDAITIS V,BARZDAITIS V V,et al.New deep groove ball bearings high frequencies vibration testing[J].Mechanika,2014,20(3):287-293.
[5] LEE R T,HWANG Y C,CHIOU Y C.Lapping of ultra-precision ball surfaces:part I concentric V-groove lapping system[J].International journal of machine tools & manufacture,2006,46(10):1146-1156.
[6] 郑斌,袁巨龙,赵萍,等.变曲率沟槽精密球研磨加工优化实验研究[J].表面技术,2017(2):214-219.
[7] ZHOU F F,YUAN J L,LYU B H,et al.Kinematics and trajectory in processing precision balls with eccentric plate and variable-radius V-groove[J].International journal of advanced manufacturing technology,2015,84(9/10/11/12):1-12.
[8] 吕冰海.陶瓷球双转盘研磨方式及成球机理的研究[D].哈尔滨:哈尔滨工业大学,2007.
[9] LI G G,GAO R Z,ZHANG J J,et al.The Modeling and analysis of grinding mechanics on bearing balls[J].Machinery design & manufacture,2014(2):236-238.
[10] 周芬芬.变曲率沟槽球体加工方式及其成球机理研究[D].杭州:浙江工业大学,2016.
[11] 李国广.钢球精密研磨机理及研球工艺研究[D].邯郸:河北工程大学,2014.
[12] LUO R,X L M,ZHA T J,et al.Modeling and simulation of surface roughness for spherical grinding[J].Journal of Shanghai Jiao Tong University,2013,47(5):709-714.
[13] 李伟,戴杰.BCB砂轮ELID磨削单晶硅工艺实验研究[J].浙江工业大学学报,2016,44(3):275-278.
[14] 何荣军,卢艳,王钧,等.基于AHP模糊评价法在草菇蛋卷研制中的应用[J].浙江工业大学学报,2015,43(1):73-76.
[15] 杨庆华,占伟涛,吴海伟,等.基于正交试验、BP神经网络和遗传算法的冷挤压模具优化设计方法[J].浙江工业大学学报,2015,43(3):251-256.
[16] 中华人民共和国国家质量监督检验检疫总局.中华人民共和国国家标准——滚动轴承陶瓷球:GB/T 308.2—2013[S].北京:中国标准出版社,2013:2-12.