表面气中放电辅助修整非金属基金刚石砂轮的研究
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摘要
表面气中放电辅助修整非金属基金刚石砂轮技术是一种新型的特种加工修整超硬磨料砂轮技术。该修整技术减少了对液体介质的依赖,可应用于精密磨床的在线修整;该方法拓宽了放电修整砂轮的应用范围,使得原先只适用于修整金属基金刚石砂轮的火花放电技术,同时适用于树脂结合剂等非导电性结合剂金刚石砂轮的修整。本文对放电去除砂轮结合剂的基本原理,砂轮表面形貌的参数控制技术等进行了研究。
文章对不同放电介质影响火花放电修整金属基金刚石砂轮进行了研究。以压缩空气、水雾气、雾状乳化油三种介质为例,进行实验,详细分析了不同放电介质对火花放电修整金属基金刚石砂轮的修整表面形貌和修整效率的影响。
针对传统电火花放电修整非导电性和弱导电性超硬磨料砂轮的局限性,在提出表面辅助细小电极法和表面涂覆导电性粉末法的基础上,分别进行了简单实验来验证两种方法的实际操作有效性,最终在比较实验数据结果的基础上,决定提出表面涂覆导电性粉末方法来实验火花放电修整非金属基金刚石砂轮的技术方案。详细分析了金刚石磨粒与结合剂两种材料热电物理性能差异,阐述了放电修整金刚石砂轮技术的蚀除金属结合剂和树脂结合剂机理。
在电火花成形机床上对树脂结合剂金刚石砂轮进行了一系列不同工艺参数的放电修锐实验。实验研究了放电峰值电流、脉冲宽度、开路电压等工艺参数对砂轮表面形貌的影响。实验结果表明:本文提出的树脂结合剂金刚石砂轮表面涂覆一层辅助放电材料后在进行基于表面气中放电修整的技术方案是可行的。放电修整工艺参数对砂轮表面轮廓形貌的影响规律如下:放电峰值电流是影响砂轮表面形貌的最主要因素,适合该方法修整树脂结合剂金刚石砂轮的峰值电流为1A-3A;脉冲宽度对砂轮修整后的表面形貌有一定的影响,但相比峰值电流,影响作用比较小,适合该方法修整树脂结合剂金刚石砂轮的脉冲宽度为10μs-50μs;开路电压对砂轮表面形貌没有明显影响。
A novel truing and dressing technology on super-abrasive grinding wheel, named surface dry-electrical discharge assisted truing and dressing of non-metal bonded diamond grinding wheel (SDDD), has been proposed in this paper. SDDD process eliminates vast dielectric liquid and produces less corrosion and pollution to function units in contrast EDD. This method widening the application range of EDD, make EDD method can be used to truing and dressing the non-metal bonded diamond grinding wheel, like resin-bonded diamond wheel. In this paper, the mechanism of the selective removal of the bond, as well as wheel surface profiles and topography control technologies of SDDD process have been systematically studied combining methods of theoretical analysis and experimental study. It will have an important theoretical value and practical significance not only for the cost reducing and increasing efficiency but also for the promoting the development and application of SDDD technology on preparation of super-abrasive grinding wheel.
In this paper, in order to understand the relationship between discharge and EDM process, impressed air, emulsification oil mirage, water mirage are adopted in this experimental. In this experimental, first, Optical Microscopy (OM) was used to analyses the topography of diamond wheel after truing; Then compared the diamond wheels’truing ratio under different discharge mediums; It is indicated that emulsification oil mirage medium can produce the best ground surface and good truing ratio. Impressed air medium produce the lowest ratio and the worst ground surface, water mirage medium produce the similar truing ratio with emulsification oil mirage medium.
Conventional EDD technology shows important limitations that it is only applicable to metal-bonded wheels. In this paper, one of the most important things is proposed novel SDDD technology which can truing and dressing non-metal super-abrasive grinding wheels such as resin-bonded diamond wheel by means of covering electrical material on the surface of wheel. The principle of removing resin bond during SDDD process is illustrated. The thermal and electrical physical properties differences between bonds and diamond abrasives are analyzed. At the same time, the mechanism of removal of the bond and revealing diamond grains has been studied.
A series of dressing experiments were carried out on a TROOP434 Die-Sinking Electrical Discharge Machine according the bond removal mechanism and thermal propagation model. The influence of process parameters including discharge current, pulse duration, and discharge voltage on dressing quality was systematically studied with experiments. The condition of the wheel before and after SDDD was analyzed by to find change. Wheel surface topographies before and after dressing was observed by optical microscope (model: KEYENCE VH-800 Digital HD).
Truing and dressing the resin-bond diamond wheel by SDDD experiments results indicated that discharge current had direct influence on the wheel surface topography and the performance of diamond grains, the suitable discharge current in SDDD is 1-3A. As well as, the pulse duration had less influence on the wheel surface topography, the suitable pulse duration in SDDD is 10μs-50μs.The discharge voltage had no influence on dressing quality and efficiency. From this, we know the discharge current and pulse duration are the chief parameters which can affect dressing quality. In the same time, the experimental shows the conductive performance of the assisted powder and the servo precision of the feed mechanism had important effects to the surface topography.
文章对不同放电介质影响火花放电修整金属基金刚石砂轮进行了研究。以压缩空气、水雾气、雾状乳化油三种介质为例,进行实验,详细分析了不同放电介质对火花放电修整金属基金刚石砂轮的修整表面形貌和修整效率的影响。
针对传统电火花放电修整非导电性和弱导电性超硬磨料砂轮的局限性,在提出表面辅助细小电极法和表面涂覆导电性粉末法的基础上,分别进行了简单实验来验证两种方法的实际操作有效性,最终在比较实验数据结果的基础上,决定提出表面涂覆导电性粉末方法来实验火花放电修整非金属基金刚石砂轮的技术方案。详细分析了金刚石磨粒与结合剂两种材料热电物理性能差异,阐述了放电修整金刚石砂轮技术的蚀除金属结合剂和树脂结合剂机理。
在电火花成形机床上对树脂结合剂金刚石砂轮进行了一系列不同工艺参数的放电修锐实验。实验研究了放电峰值电流、脉冲宽度、开路电压等工艺参数对砂轮表面形貌的影响。实验结果表明:本文提出的树脂结合剂金刚石砂轮表面涂覆一层辅助放电材料后在进行基于表面气中放电修整的技术方案是可行的。放电修整工艺参数对砂轮表面轮廓形貌的影响规律如下:放电峰值电流是影响砂轮表面形貌的最主要因素,适合该方法修整树脂结合剂金刚石砂轮的峰值电流为1A-3A;脉冲宽度对砂轮修整后的表面形貌有一定的影响,但相比峰值电流,影响作用比较小,适合该方法修整树脂结合剂金刚石砂轮的脉冲宽度为10μs-50μs;开路电压对砂轮表面形貌没有明显影响。
A novel truing and dressing technology on super-abrasive grinding wheel, named surface dry-electrical discharge assisted truing and dressing of non-metal bonded diamond grinding wheel (SDDD), has been proposed in this paper. SDDD process eliminates vast dielectric liquid and produces less corrosion and pollution to function units in contrast EDD. This method widening the application range of EDD, make EDD method can be used to truing and dressing the non-metal bonded diamond grinding wheel, like resin-bonded diamond wheel. In this paper, the mechanism of the selective removal of the bond, as well as wheel surface profiles and topography control technologies of SDDD process have been systematically studied combining methods of theoretical analysis and experimental study. It will have an important theoretical value and practical significance not only for the cost reducing and increasing efficiency but also for the promoting the development and application of SDDD technology on preparation of super-abrasive grinding wheel.
In this paper, in order to understand the relationship between discharge and EDM process, impressed air, emulsification oil mirage, water mirage are adopted in this experimental. In this experimental, first, Optical Microscopy (OM) was used to analyses the topography of diamond wheel after truing; Then compared the diamond wheels’truing ratio under different discharge mediums; It is indicated that emulsification oil mirage medium can produce the best ground surface and good truing ratio. Impressed air medium produce the lowest ratio and the worst ground surface, water mirage medium produce the similar truing ratio with emulsification oil mirage medium.
Conventional EDD technology shows important limitations that it is only applicable to metal-bonded wheels. In this paper, one of the most important things is proposed novel SDDD technology which can truing and dressing non-metal super-abrasive grinding wheels such as resin-bonded diamond wheel by means of covering electrical material on the surface of wheel. The principle of removing resin bond during SDDD process is illustrated. The thermal and electrical physical properties differences between bonds and diamond abrasives are analyzed. At the same time, the mechanism of removal of the bond and revealing diamond grains has been studied.
A series of dressing experiments were carried out on a TROOP434 Die-Sinking Electrical Discharge Machine according the bond removal mechanism and thermal propagation model. The influence of process parameters including discharge current, pulse duration, and discharge voltage on dressing quality was systematically studied with experiments. The condition of the wheel before and after SDDD was analyzed by to find change. Wheel surface topographies before and after dressing was observed by optical microscope (model: KEYENCE VH-800 Digital HD).
Truing and dressing the resin-bond diamond wheel by SDDD experiments results indicated that discharge current had direct influence on the wheel surface topography and the performance of diamond grains, the suitable discharge current in SDDD is 1-3A. As well as, the pulse duration had less influence on the wheel surface topography, the suitable pulse duration in SDDD is 10μs-50μs.The discharge voltage had no influence on dressing quality and efficiency. From this, we know the discharge current and pulse duration are the chief parameters which can affect dressing quality. In the same time, the experimental shows the conductive performance of the assisted powder and the servo precision of the feed mechanism had important effects to the surface topography.
引文
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