高效软性磨粒流精密加工方法及其测控系统
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摘要
模具是工业产品生产用的重要工艺装备，其使用量大，影响面广，是高新技术产业发展的重要保证。在现代工业生产中，超过60%的工业产品需要使用模具。结构化表面模具限制了传统抛光工具与被加工表面的接触。磨粒流加工方法由于强粘度磨粒流的强阻力会破坏结构化表面，磨粒的往复运动加工形式无法做到随机的磨削，限制了其用于镜面级表面粗糙度的超精密加工。软性磨粒流加工方法可利用湍流的随机性引导磨粒进行随机磨削。为了提高软性磨粒流加工方法的效率，必须设计高效加工方法及测控系统，采用分离高压驱动方法，并对精密加工的全过程进行监控。
研究了软性磨粒流加工方法，并对对液体和磨粒的运动情况做出了模拟和分析。液体运动形态具有两个作用。一方面，对壁面施加法向应力和切向应力；另一方面，液体运动形态也是磨粒运动的主要能量来源，决定了磨粒的运动形态。磨粒对多相流的影响程度可用颗粒质量载荷率、颗粒动量载荷率和颗粒体积分数三个概念确定，其中10%和50%是不同性质磨粒流的分界线。机油具有较大壁面压力和剪切力，更容易造成壁面结构破坏，适用于光整加工的粗加工阶段，用以大量去除材料，水则适用于光整加工的细加工阶段。大直径磨粒获得的速度较大，适用于光整加工的粗加工阶段，直径较小的磨粒能在较长距离保持速度，有利于与工件表面突起进行连续接触，适用于细加工阶段。壁面处湍动能不为零，可引导磨粒做随机切削，提高表面粗糙度。磨粒的材料去除和粗糙度的提高需依靠不同直径的磨粒。小直径磨粒对于液体流动的跟随性较好，利用液体的湍流运动的随机性，可以进行随机的微力微量的切削，加工的随机性有利于粗糙度的提高。大直径磨粒能和壁面长时间的刮擦，碰撞的次数也多于小直径磨粒，可以带来更好的材料去除率。
对软性磨粒流高效加工方法及测控系统进行了全面分析。讨论了软性磨粒流的各种高效加工方法，并对分离送料方法及装置做了详细的说明。对测控系统的嵌入式操作系统的实时性和任务切换做了具体说明。固液分离方式比固液混合方式更高效，可减少泵压力的浪费和泵体的损坏，可提高输出压力到20MPa以上，分离式送料方法和装置使磨粒浓度可控，提高了加工效率。采用CAN总线和嵌入式实时操作系统可以保证测控任务的实时性。采用模糊控制系统，做到了液体和磨料的输出流量稳定，可将输出流量稳定在6%。采用自律控制方法后，系统的可靠性大幅提高。液体流量和磨粒浓度按工段自动调节，满足了实际加工需求。
对软性磨粒流的实验环节进行了研究。建立了电源和液源的一致性关系式，对液压、液流和液功推导了应用关系式。工作流道的能量需求属于高压高速小流量类型。在输送液体介质方面适合的泵有离心泵和齿轮泵，输送固体介质方面，隔膜泵满足要求。实验表明，软性磨粒流加工粗糙度目前可以达到0.06μm。通过连续摄像验证了颗粒运动的轨迹及随机性。实验表明，采用高效加工方法及测控系统后加工效率可以提高40%。
The mold is an important equipment for industrial production, which is an importantguarantee for the development of the high-tech industry for large quantity use and wide influence.In modern industrial production, more than60%industrial products require the use of the mold.The structural surface mold limits the contact of traditional polishing tool and the machiningsurface. Abrasive flow machining method will destroy the structural surface because of thestrong resistance of strong viscosity. Abrasive reciprocating motion can not do random grinding,limiting its application for mirror level surface roughness in ultra precision machining. Softabrasive flow machining method can utilize the turbulent random guiding abrasive randomgrinding. In order to improve the efficiency of soft abrasive flow machining, it is necessary toput forward an efficient method and measurement and control system, with separation, highpressure driving method, and the whole process monitoring.
The soft abrasive flow processing method was studied. Liquid and particle motionsimulation and analysis were made. The movement form of liquid has two functions. On onehand, normal stress and tangential stress is applied on the wall surface; on the other hand, themovement of liquid motion is also a major energy source to determine the particle movement.Abrasive particle influences multiphase flow with particle mass loading rate, particle momentumload rate and the particle volume fraction of which10%and50%are boundaries for differentabrasive flow. Oil has great wall pressure and shearing force, more likely to cause damage ofwall structure, is suitable for the finishing of rough machining stage for a large number ofmaterial removal. Water is suitable for the finishing of fine processing stages. Large diameterabrasive speed gain is larger, suitable for the finishing of rough machining phase. The smallerdiameter abrasive can maintain speed in longer distance, which is conducive to the continuouscontact with workpiece surface protrusions for fine processing stages. Wall turbulence kineticenergy is not zero, which can guide the abrasive doing random cutting and improve the surfaceroughness. Abrasive material removal and surface roughness increase depend on differentdiameter of the abrasive grain. Small diameter abrasive follow liquid flow better with random micro cutting in favor of roughness improve. Large diameter abrasive long time scraping on wall,with collision frequency more than small diameter abrasive, can lead to better material removalrate.
Comprehensive analysis of soft abrasive flow processing method and measurement andcontrol system was undertaken. Discussion of soft abrasive flow of all sorts of efficientprocessing methods, and the separation feeding method and device were described in detail.Embedded real-time operating system and task switching of measurement and control systemwere illustrated in detail. Solid-liquid separation is more efficient than solid-liquid mixing way,which can reduce the pressure waste and the pump body damage and improve the outputpressure to above of20MPa. Separate feeding method enables particle concentration control, toimprove the efficiency of processing. Using CAN bus and embedded real-time operating systemcan guarantee the real-time of control tasks. By using the fuzzy control, the output flow is stableat6%. With autonomous control method, the reliability of the system is greatly improved. Liquidflow volume and particle concentration are automatically adjusted by section, meeting theprocessing needs.
The soft abrasive flow experiments were studied. Power source and the fluid sourcecoherence relation were established. The application relationship of fluid pressure, flow volumeand power were derived. Energy demand of work flow channel is high pressure, high speed andsmall flow types. During the delivery of liquid medium, centrifugal pump and gear pump arebetter. Transportation of solid medium needs the diaphragm pump to meet the requirements.Experimental results show that, the soft abrasive flow machining roughness can now reach0.06μm. Through continuous imaging particle motion trajectory and randomness are proved.Experimental results show that, using an efficient processing method and measurement andcontrol system the efficiency is increased by40%.
研究了软性磨粒流加工方法，并对对液体和磨粒的运动情况做出了模拟和分析。液体运动形态具有两个作用。一方面，对壁面施加法向应力和切向应力；另一方面，液体运动形态也是磨粒运动的主要能量来源，决定了磨粒的运动形态。磨粒对多相流的影响程度可用颗粒质量载荷率、颗粒动量载荷率和颗粒体积分数三个概念确定，其中10%和50%是不同性质磨粒流的分界线。机油具有较大壁面压力和剪切力，更容易造成壁面结构破坏，适用于光整加工的粗加工阶段，用以大量去除材料，水则适用于光整加工的细加工阶段。大直径磨粒获得的速度较大，适用于光整加工的粗加工阶段，直径较小的磨粒能在较长距离保持速度，有利于与工件表面突起进行连续接触，适用于细加工阶段。壁面处湍动能不为零，可引导磨粒做随机切削，提高表面粗糙度。磨粒的材料去除和粗糙度的提高需依靠不同直径的磨粒。小直径磨粒对于液体流动的跟随性较好，利用液体的湍流运动的随机性，可以进行随机的微力微量的切削，加工的随机性有利于粗糙度的提高。大直径磨粒能和壁面长时间的刮擦，碰撞的次数也多于小直径磨粒，可以带来更好的材料去除率。
对软性磨粒流高效加工方法及测控系统进行了全面分析。讨论了软性磨粒流的各种高效加工方法，并对分离送料方法及装置做了详细的说明。对测控系统的嵌入式操作系统的实时性和任务切换做了具体说明。固液分离方式比固液混合方式更高效，可减少泵压力的浪费和泵体的损坏，可提高输出压力到20MPa以上，分离式送料方法和装置使磨粒浓度可控，提高了加工效率。采用CAN总线和嵌入式实时操作系统可以保证测控任务的实时性。采用模糊控制系统，做到了液体和磨料的输出流量稳定，可将输出流量稳定在6%。采用自律控制方法后，系统的可靠性大幅提高。液体流量和磨粒浓度按工段自动调节，满足了实际加工需求。
对软性磨粒流的实验环节进行了研究。建立了电源和液源的一致性关系式，对液压、液流和液功推导了应用关系式。工作流道的能量需求属于高压高速小流量类型。在输送液体介质方面适合的泵有离心泵和齿轮泵，输送固体介质方面，隔膜泵满足要求。实验表明，软性磨粒流加工粗糙度目前可以达到0.06μm。通过连续摄像验证了颗粒运动的轨迹及随机性。实验表明，采用高效加工方法及测控系统后加工效率可以提高40%。
The mold is an important equipment for industrial production, which is an importantguarantee for the development of the high-tech industry for large quantity use and wide influence.In modern industrial production, more than60%industrial products require the use of the mold.The structural surface mold limits the contact of traditional polishing tool and the machiningsurface. Abrasive flow machining method will destroy the structural surface because of thestrong resistance of strong viscosity. Abrasive reciprocating motion can not do random grinding,limiting its application for mirror level surface roughness in ultra precision machining. Softabrasive flow machining method can utilize the turbulent random guiding abrasive randomgrinding. In order to improve the efficiency of soft abrasive flow machining, it is necessary toput forward an efficient method and measurement and control system, with separation, highpressure driving method, and the whole process monitoring.
The soft abrasive flow processing method was studied. Liquid and particle motionsimulation and analysis were made. The movement form of liquid has two functions. On onehand, normal stress and tangential stress is applied on the wall surface; on the other hand, themovement of liquid motion is also a major energy source to determine the particle movement.Abrasive particle influences multiphase flow with particle mass loading rate, particle momentumload rate and the particle volume fraction of which10%and50%are boundaries for differentabrasive flow. Oil has great wall pressure and shearing force, more likely to cause damage ofwall structure, is suitable for the finishing of rough machining stage for a large number ofmaterial removal. Water is suitable for the finishing of fine processing stages. Large diameterabrasive speed gain is larger, suitable for the finishing of rough machining phase. The smallerdiameter abrasive can maintain speed in longer distance, which is conducive to the continuouscontact with workpiece surface protrusions for fine processing stages. Wall turbulence kineticenergy is not zero, which can guide the abrasive doing random cutting and improve the surfaceroughness. Abrasive material removal and surface roughness increase depend on differentdiameter of the abrasive grain. Small diameter abrasive follow liquid flow better with random micro cutting in favor of roughness improve. Large diameter abrasive long time scraping on wall,with collision frequency more than small diameter abrasive, can lead to better material removalrate.
Comprehensive analysis of soft abrasive flow processing method and measurement andcontrol system was undertaken. Discussion of soft abrasive flow of all sorts of efficientprocessing methods, and the separation feeding method and device were described in detail.Embedded real-time operating system and task switching of measurement and control systemwere illustrated in detail. Solid-liquid separation is more efficient than solid-liquid mixing way,which can reduce the pressure waste and the pump body damage and improve the outputpressure to above of20MPa. Separate feeding method enables particle concentration control, toimprove the efficiency of processing. Using CAN bus and embedded real-time operating systemcan guarantee the real-time of control tasks. By using the fuzzy control, the output flow is stableat6%. With autonomous control method, the reliability of the system is greatly improved. Liquidflow volume and particle concentration are automatically adjusted by section, meeting theprocessing needs.
The soft abrasive flow experiments were studied. Power source and the fluid sourcecoherence relation were established. The application relationship of fluid pressure, flow volumeand power were derived. Energy demand of work flow channel is high pressure, high speed andsmall flow types. During the delivery of liquid medium, centrifugal pump and gear pump arebetter. Transportation of solid medium needs the diaphragm pump to meet the requirements.Experimental results show that, the soft abrasive flow machining roughness can now reach0.06μm. Through continuous imaging particle motion trajectory and randomness are proved.Experimental results show that, using an efficient processing method and measurement andcontrol system the efficiency is increased by40%.
引文
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