工程陶瓷超声磨削试验机床的电气控制与基础实验研究
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摘要
由于工程陶瓷材料具有的优良物理、化学性能,使它在一些特殊领域如高温、腐蚀以及易磨损等场所有着诱人的应用前景,但正是由于这些优良的性能,使得对其加工也带来了困难。目前一般采用特种加工方法例如超声磨削复合加工。
本文对工程陶瓷的应用及其国内外超声加工概况以及陶瓷超声磨削加工设备的组成、工艺要求等作了详细的介绍。并对超声磨削加工机理进行了分析研究。在超声加工过程中,相关电气控制系统起到非常重要的作用,其性能参数的好坏,将直接影响到加工的效果甚至设备运行安全,因此对相关设备的设计研制和选购尤为重要。本文对一些重要的电气控制设备如超声电源、交流变频电机、变频器以及附属装置的结构原理、性能参数作了分析介绍。
同时,为了实现对陶瓷进行恒转速磨削,以便达到更好的加工效果,对驱动磨轮主轴的交流变频电机采用了计算机数字闭环控制,本文在数学模型的基础之上对其进行了分析讨论。
另外,本文在超声磨削加工中引入弹性能概念,结合断裂模型以解释课题实验中Al_2O_3工程陶瓷的超声与机械磨削加工的对比结果。
Possessing excellent performance of physics and chemistry, engineering ceramics (EC) have attractive applied foreground in some special fields of high temperature, erosive and wearing et al. But it just is the excellent performance that bring handicaps to machining it. At present, special type machining such as ultrasonic grinding machining is ordinarily used in processing engineering ceramics.
Engineering ceramics’application and its general situation of ultrasonic machining in domestic and abroad is introduced. The composing and technical requires of engineering ceramics’ultrasonic grinding machining is detailedly introduced. The mechanism of ultrasonic grinding machining is also analyzed and researched in this article.
The related electronic control systems play a important role in the process of ultrasonic grinding machining engineering ceramics, its parameter of performance will directly affect the effect of machining even the safety of equipment running. Therefore, it is important to design, manufacture, choose and buy related equipment. The structural principle and parameter of performance of some important electronic control equipment such as ultrasonic power supply, AC frequency conversion electromotor, transducer and their affiliated facilities are analyzed and introduced.
At the same time, in order to grind engineering ceramics in constant rotate speed, so that the better machining effect can be achieved, the grinding axis driver—AC frequency conversion electromotor is numeric closed-loop controlled through computer, the process is analyzed based on mathematical model in this article.
In addition, the conception of elasticity energy is introduced in the article, and it is combined with the model of fracture toughness so as to explain the contrastive results between ultrasonic and mechanical grinding machining Al2O3 engineering ceramic in experiment.
本文对工程陶瓷的应用及其国内外超声加工概况以及陶瓷超声磨削加工设备的组成、工艺要求等作了详细的介绍。并对超声磨削加工机理进行了分析研究。在超声加工过程中,相关电气控制系统起到非常重要的作用,其性能参数的好坏,将直接影响到加工的效果甚至设备运行安全,因此对相关设备的设计研制和选购尤为重要。本文对一些重要的电气控制设备如超声电源、交流变频电机、变频器以及附属装置的结构原理、性能参数作了分析介绍。
同时,为了实现对陶瓷进行恒转速磨削,以便达到更好的加工效果,对驱动磨轮主轴的交流变频电机采用了计算机数字闭环控制,本文在数学模型的基础之上对其进行了分析讨论。
另外,本文在超声磨削加工中引入弹性能概念,结合断裂模型以解释课题实验中Al_2O_3工程陶瓷的超声与机械磨削加工的对比结果。
Possessing excellent performance of physics and chemistry, engineering ceramics (EC) have attractive applied foreground in some special fields of high temperature, erosive and wearing et al. But it just is the excellent performance that bring handicaps to machining it. At present, special type machining such as ultrasonic grinding machining is ordinarily used in processing engineering ceramics.
Engineering ceramics’application and its general situation of ultrasonic machining in domestic and abroad is introduced. The composing and technical requires of engineering ceramics’ultrasonic grinding machining is detailedly introduced. The mechanism of ultrasonic grinding machining is also analyzed and researched in this article.
The related electronic control systems play a important role in the process of ultrasonic grinding machining engineering ceramics, its parameter of performance will directly affect the effect of machining even the safety of equipment running. Therefore, it is important to design, manufacture, choose and buy related equipment. The structural principle and parameter of performance of some important electronic control equipment such as ultrasonic power supply, AC frequency conversion electromotor, transducer and their affiliated facilities are analyzed and introduced.
At the same time, in order to grind engineering ceramics in constant rotate speed, so that the better machining effect can be achieved, the grinding axis driver—AC frequency conversion electromotor is numeric closed-loop controlled through computer, the process is analyzed based on mathematical model in this article.
In addition, the conception of elasticity energy is introduced in the article, and it is combined with the model of fracture toughness so as to explain the contrastive results between ultrasonic and mechanical grinding machining Al2O3 engineering ceramic in experiment.
引文
[1]张勤河,张建华,高军,工程陶瓷材料的应用,现代陶瓷技术,1998,4:21～24
[2]徐政,倪宏伟,现代功能陶瓷,北京:国防工业出版社,1998,9
[3]段继光,工程陶瓷技术, 湖南长沙:湖南科学技术出版社,1994,6
[4]艾兴,萧虹,陶瓷刀具切削加工,北京:机械工业出版社,1988
[5]肖诗纲,刀具材料及其合理选择,北京:机械工业出版社,1988
[6]仇启源,新型陶瓷刀具,北京:国防工业出版,1990
[7]黄传真,李兆前,艾兴等,热压工艺参数对新型陶瓷刀具材料 JX-2-1 力学性能的影响,现代技术陶瓷,1996,4:3～5
[8] Lo Casto, S., Lo Valvo, E., Piacentini, M.,et al. Cutting temperatures evaluation in ceramic tools: experimental tests, numerical analysis and SEM observations, Annals of the CIRP,1994,43:73～76
[9]Anon, Ceramic Bearing for Volume Application, Industrial Diamond Review,1990,50:122～124
[10]B.Bhusban, Silicon Nitride Bearings for Extreme Operating Conditions, ASLE Trans,1982,25:417～428
[11] Dalal, H. M.,Chiu. Y. P.,Rabinowicz, E.,Evaluation of Hot Pressed Silicon Nitride as a Rolling Bearing Materials, ASLE Trans ,1975,18:211～221
[12]王炜,陶瓷在机械工业上的应用,机电工程,1991,4:97～100
[13]彭惠,民用陶瓷制造的超精密加工(译),国外机械加工技术,1986,2:88～91
[14]Charies.River. Associates, Advanced Ceramic Material, New Jersey : Noyes Publications, 1985:668～670
[15]罗米,复合装甲-“钢铁三明治”,兵器知识,2005,8:64～68
[16]陶瓷应用的新天地,http://www.ahuaxue.com/ShowArticle.asp?ArticleID=1013,2005,9
[17]高瑞平,李晓光,先进陶瓷物理与化学原理及技术,北京:科学出版社,2000,9
[18]王瑞刚,潘伟,蒋蒙宁等,可加工陶瓷及工程陶瓷加工技术现状及发展,硅酸盐通报,2001,3:27～35
[19]潘洪平,梁迎春,董申,陶瓷材料加工技术发展概况,工具技术,1999,33:3～6
[20]李湘钒,工程陶瓷零件的车削工艺探讨,苏州大学学报,2002,22:70～73
[21]水谷胜己,谷先盛彦等 ,精密工学会志,1986,52:1786
[22]詹捷,陈小安,王永刚,工程陶瓷材料精密加工技术,机械工程师,1998,6:11～12
[23] Apiwat Muttamara, Yasushi Fukuzawa ,Naotake Mohri, Takayuki Tani,Probabilityof precision micro-machining of insulating Si3N4 ceramics by EDM,Journal of Materials Processing Technology ,2003, 140: 243～247
[24]Jahanmir,S.Ramulu,M.koshy.P, Machining of ceramics and composites, New York,Marcel Dekker,Inc,1999:559～578
[25]刘殿通,超声磨削加工机床及其电源的研制,[硕士学位论文],天津,天津大学,2001, 1:4
[26]曹凤国,张勤俭,超声加工技术的研究现状及其发展趋势,电加工与模具,2005 增刊, 25～27
[27]袁松梅, 赵万生, 刘维东,超声电火花复合加工的研究进展,航空精密制造技术,1998, 34:17～20
[28]Kenrichi Ishikawa , Hitoshi Suwabe , Tetsuhiro Nishide, A study on combined vibration drilling by ultrasonic and low2frequency vibrations for hard and brittle materials, Precision Engineering ,1998,22:196～205
[29]Hu P,Zhang J M,Pei Z J,Modeling of material removal rate inrotary ultrasonic machining:designed experiments, Journal of Material Processing Technology,2002,129:339～344
[30]吕正兵,徐家文,工程陶瓷超声加工的基础试验研究,2004,2:57～60
[31]杨卫平,徐家文,工程陶瓷型面的超声磨削装置设计,南昌航空工业学院学报(自然科学版),2003,4:5～8
[32]杨大春, 云乃彰, 严德荣, 硬脆金属的超声电解复合加工研究, 电加工与模具, 2002,2:31～33
[33]张辽远, 史维明, 薛航,超声复合加工玛瑙的实验研究, 中国兵工论文集, 2000:123～140
[34]章伟, 陈澄洲, 张发英, 电解、磨粒、超声复合加工技术及其加工表面粗糙度的预测方法, 工具技术,1998,32,2:20～23
[35] Zhao Wansheng , Wang Zhenlong , Di Shichun , et al, Ultrasonic and electric discharge machining to deep and small hole on titanium alloy, Journal of Materials Processing Technology,2002,120:101～106
[36]钱军, 高长水, 工件激振式复合电火花微细孔加工, 航空精密制造技术, 1997,33: 18～20
[37]范国良,陈传良,超声加工概况和未来展望,电加工,1994,6:10
[38]张云电,超声加工及其应用,北京:国防工业出版社,1995,9
[39]张清纯,陶瓷材料的力学性能,北京:科学出版社,1987,12
[40]郝虎在,田玉明,黄平,电子陶瓷材料物理,北京:中国铁道出版社,2002,5:
[41]龚江宏,陶瓷材料断裂力学,北京:清华大学出版社,2001,9
[42]金志浩,高积强,乔冠军,工程陶瓷材料,西安:西安交通大学出版社,2000,9
[43]刘晋春,赵家齐,赵万生,特种加工,机械工业出版社, 2005,5
[44]刘子旭,陶瓷磨削机理,磨床与磨削,1998,1:36～42
[45]任敬心,华定安,磨削原理,西安:西北工业大学出版社,1988,6
[46]林仲茂,超声变幅杆的原理和设计,科学出版社,1987,10
[47]陈桂生,超声换能器设计,北京:海洋出版社,1984
[48]鲍善惠,超声发生器中的特殊电路,http://www.china-ultrasonic.net/cstsdl.htm,2005,9
[49]李富龙,压电陶瓷谐振频率变化的分析研究及其控制,南京航空航天大学第七届研究生学术会议论文集,2005,11
[50]黄立培,张学,变频器应用技术及电动机调速,人民邮电出版社,1998,7
[51]陈国呈,PWM 变频调速技术,机械工业出版社,1998,7
[52]吴忠智,黄立培,吴加林,调速用变频器及配套设备选用指南,2000,3
[53]王正元,交流电动机变频调速节能技术指南—变频调速系统中交流电动机和变频调速装置的选择,电力电子,2004,24:58～63
[54]刘雪波,交流变频调速电机设计,电机技术,2001,2
[55]李嗣福,计算机控制基础,合肥:科学技术出版社,2001,9
[56]童幸生,袁耀华,工程陶瓷的磨削加工,三峡大学学报(自然科学版),2001,23:165～168
[2]徐政,倪宏伟,现代功能陶瓷,北京:国防工业出版社,1998,9
[3]段继光,工程陶瓷技术, 湖南长沙:湖南科学技术出版社,1994,6
[4]艾兴,萧虹,陶瓷刀具切削加工,北京:机械工业出版社,1988
[5]肖诗纲,刀具材料及其合理选择,北京:机械工业出版社,1988
[6]仇启源,新型陶瓷刀具,北京:国防工业出版,1990
[7]黄传真,李兆前,艾兴等,热压工艺参数对新型陶瓷刀具材料 JX-2-1 力学性能的影响,现代技术陶瓷,1996,4:3～5
[8] Lo Casto, S., Lo Valvo, E., Piacentini, M.,et al. Cutting temperatures evaluation in ceramic tools: experimental tests, numerical analysis and SEM observations, Annals of the CIRP,1994,43:73～76
[9]Anon, Ceramic Bearing for Volume Application, Industrial Diamond Review,1990,50:122～124
[10]B.Bhusban, Silicon Nitride Bearings for Extreme Operating Conditions, ASLE Trans,1982,25:417～428
[11] Dalal, H. M.,Chiu. Y. P.,Rabinowicz, E.,Evaluation of Hot Pressed Silicon Nitride as a Rolling Bearing Materials, ASLE Trans ,1975,18:211～221
[12]王炜,陶瓷在机械工业上的应用,机电工程,1991,4:97～100
[13]彭惠,民用陶瓷制造的超精密加工(译),国外机械加工技术,1986,2:88～91
[14]Charies.River. Associates, Advanced Ceramic Material, New Jersey : Noyes Publications, 1985:668～670
[15]罗米,复合装甲-“钢铁三明治”,兵器知识,2005,8:64～68
[16]陶瓷应用的新天地,http://www.ahuaxue.com/ShowArticle.asp?ArticleID=1013,2005,9
[17]高瑞平,李晓光,先进陶瓷物理与化学原理及技术,北京:科学出版社,2000,9
[18]王瑞刚,潘伟,蒋蒙宁等,可加工陶瓷及工程陶瓷加工技术现状及发展,硅酸盐通报,2001,3:27～35
[19]潘洪平,梁迎春,董申,陶瓷材料加工技术发展概况,工具技术,1999,33:3～6
[20]李湘钒,工程陶瓷零件的车削工艺探讨,苏州大学学报,2002,22:70～73
[21]水谷胜己,谷先盛彦等 ,精密工学会志,1986,52:1786
[22]詹捷,陈小安,王永刚,工程陶瓷材料精密加工技术,机械工程师,1998,6:11～12
[23] Apiwat Muttamara, Yasushi Fukuzawa ,Naotake Mohri, Takayuki Tani,Probabilityof precision micro-machining of insulating Si3N4 ceramics by EDM,Journal of Materials Processing Technology ,2003, 140: 243～247
[24]Jahanmir,S.Ramulu,M.koshy.P, Machining of ceramics and composites, New York,Marcel Dekker,Inc,1999:559～578
[25]刘殿通,超声磨削加工机床及其电源的研制,[硕士学位论文],天津,天津大学,2001, 1:4
[26]曹凤国,张勤俭,超声加工技术的研究现状及其发展趋势,电加工与模具,2005 增刊, 25～27
[27]袁松梅, 赵万生, 刘维东,超声电火花复合加工的研究进展,航空精密制造技术,1998, 34:17～20
[28]Kenrichi Ishikawa , Hitoshi Suwabe , Tetsuhiro Nishide, A study on combined vibration drilling by ultrasonic and low2frequency vibrations for hard and brittle materials, Precision Engineering ,1998,22:196～205
[29]Hu P,Zhang J M,Pei Z J,Modeling of material removal rate inrotary ultrasonic machining:designed experiments, Journal of Material Processing Technology,2002,129:339～344
[30]吕正兵,徐家文,工程陶瓷超声加工的基础试验研究,2004,2:57～60
[31]杨卫平,徐家文,工程陶瓷型面的超声磨削装置设计,南昌航空工业学院学报(自然科学版),2003,4:5～8
[32]杨大春, 云乃彰, 严德荣, 硬脆金属的超声电解复合加工研究, 电加工与模具, 2002,2:31～33
[33]张辽远, 史维明, 薛航,超声复合加工玛瑙的实验研究, 中国兵工论文集, 2000:123～140
[34]章伟, 陈澄洲, 张发英, 电解、磨粒、超声复合加工技术及其加工表面粗糙度的预测方法, 工具技术,1998,32,2:20～23
[35] Zhao Wansheng , Wang Zhenlong , Di Shichun , et al, Ultrasonic and electric discharge machining to deep and small hole on titanium alloy, Journal of Materials Processing Technology,2002,120:101～106
[36]钱军, 高长水, 工件激振式复合电火花微细孔加工, 航空精密制造技术, 1997,33: 18～20
[37]范国良,陈传良,超声加工概况和未来展望,电加工,1994,6:10
[38]张云电,超声加工及其应用,北京:国防工业出版社,1995,9
[39]张清纯,陶瓷材料的力学性能,北京:科学出版社,1987,12
[40]郝虎在,田玉明,黄平,电子陶瓷材料物理,北京:中国铁道出版社,2002,5:
[41]龚江宏,陶瓷材料断裂力学,北京:清华大学出版社,2001,9
[42]金志浩,高积强,乔冠军,工程陶瓷材料,西安:西安交通大学出版社,2000,9
[43]刘晋春,赵家齐,赵万生,特种加工,机械工业出版社, 2005,5
[44]刘子旭,陶瓷磨削机理,磨床与磨削,1998,1:36～42
[45]任敬心,华定安,磨削原理,西安:西北工业大学出版社,1988,6
[46]林仲茂,超声变幅杆的原理和设计,科学出版社,1987,10
[47]陈桂生,超声换能器设计,北京:海洋出版社,1984
[48]鲍善惠,超声发生器中的特殊电路,http://www.china-ultrasonic.net/cstsdl.htm,2005,9
[49]李富龙,压电陶瓷谐振频率变化的分析研究及其控制,南京航空航天大学第七届研究生学术会议论文集,2005,11
[50]黄立培,张学,变频器应用技术及电动机调速,人民邮电出版社,1998,7
[51]陈国呈,PWM 变频调速技术,机械工业出版社,1998,7
[52]吴忠智,黄立培,吴加林,调速用变频器及配套设备选用指南,2000,3
[53]王正元,交流电动机变频调速节能技术指南—变频调速系统中交流电动机和变频调速装置的选择,电力电子,2004,24:58～63
[54]刘雪波,交流变频调速电机设计,电机技术,2001,2
[55]李嗣福,计算机控制基础,合肥:科学技术出版社,2001,9
[56]童幸生,袁耀华,工程陶瓷的磨削加工,三峡大学学报(自然科学版),2001,23:165～168