数控快速点磨削技术及其应用

快速点磨削（Quick-Point Grinding）是一种先进的超高速磨削技术,它集成了超高速磨削、CBN超硬磨料及CNC技术,在加工轴类零件场合具有优良的性能。介绍了快速点磨削技术的发展现状及工艺特征,分析了快速点磨削机理和材料去除机制。结果表明：砂轮的磨损机制不同于一般外圆磨削,磨削过程具有较高的绿色加工性能;通过合理控制磨削参数和磨削条件,该项技术可应用于对一些难加工材料和复杂回转表面的高质量磨削加工,由此提出了在这些领域开展应用研究的重点内容,以及推广和开发此项技术的意义。     

发展中的模具先进制造技术

介绍了模具加工的前沿技术－高速数控切削和高速数控磨削的关键技术和发展趋势，探讨了发展面向快速制造的模具特种加工技术，概述了稀土表面工程技术和纳米表面工程技术在模具制造中的应用进展。     

精密砂型数控铣削加工技术研究进展

精密砂型(芯)数控铣削加工技术是将砂型制备工艺、铸型设计及数控加工技术融合在一起,根据产品开发速度竞争而发展起来的绿色快速精密砂型制造技术,该技术制造周期短、成本低、砂型(芯)一体化制造,是一种全新的铸型快速制备加工理念,特别适合于装备开发过程中单件、小批量复杂铸件快速制造及新产品的开发试制。采用该方法制备的砂型(芯)尺寸精度高、表面质量好,可以实现复杂铸件的整体近净成形。主要综述了基于去除原理的数控加工方法的无模化精密砂型数控铣削技术的工艺特点、砂坯制备、专用设备及刀具的选择,并指出了目前还存在的问题及其发展方向。     

磨削工艺绿色度评价指标体系及影响因素分析

绿色制造作为一种现代制造模式,符合可持续发展的战略要求.磨削是一种重要机械加工方法,同时也是机械制造过程中对环境和资源影响最大的一种加工工艺,科学地评价磨削工艺绿色度、提高磨削工艺的绿色水平,对建立绿色制造系统具有重要意义.根据对磨削加工过程的绿色特性分析,建立了磨削工艺绿色度评价的指标体系,包括环境、能源、资源、经济性、生产效率、宜人度和绿色管理等方面,对各项指标的影响因素进行了分析.磨削工艺绿色度评价指标是,磨削工艺绿色度评价的量化基础,也为面向绿色制造的磨削工艺参数优化提供了理论依据.     

面向绿色制造的快速点磨削磨削液供给参数计算

高速／超高速磨削条件下,砂轮边缘的高速空气带会阻碍磨削液注入磨削区。空气带压力与砂轮速度的平方成正比。快速点磨削是一种新型高速／超高速磨削技术,接触区很小,实际磨削功率低,冷却及散热效果好。在分析了高速／超高速磨削砂轮周围旋转空气带动压力及速度分布特点的基础上,根据热力学原理及快速点磨削特点,分析并建立了磨削液的供给流量和供液速度的理论模型。在此基础上,建立了面向绿色制造的快速点磨削的磨削液喷嘴直径及供液压力的工程计算公式。     

机床主轴智能磨削工艺软件的研究与开发

以机床主轴磨削工艺方案智能推理为研究对象,研发了满足智能化制造机床主轴的磨削工艺软件。该软件汇集了机床主轴智能磨削工艺基础数据库、工艺知识库、工艺实例优选与智能推理、数控自动编程等多个模块,并应用于数控外圆磨床生产实践中。结果表明:该磨削工艺软件能显著提高主轴数控磨削工艺方案决策的准确度,决策正确率达到96%,工艺决策时间缩短约50%,从而提高加工效率。      

高效率磨粒加工技术发展及关键技术

高效率磨粒加工是先进制造方法的重要组成部分,集粗精加工与一身,达到可与车、铣和刨削等切削加工方法相媲美的金属磨除率,而且能实现对难磨材料的高性能加工。阐述了高速超高速磨削、快速点磨削、高效深切磨削、缓进给磨削、高速重负荷荒磨以及砂带磨削等高效率磨粒加工技术的国内外的发展及最新研究进展。研究了高效磨削砂轮、主轴及其轴承技术、高效率磨床、磨削液供给技术、砂轮、工件安装定位及安全防护技术以及磨削状态检测及数控技术等实现高效率磨粒加工的关键技术,分析了发展高效率磨粒加工的重要性。     

面向绿色制造的砂带磨削机理研究

针对未来绿色制造的需要，提出了采用砂带进行干磨法研究的必要性，分析了静电植砂砂带与普通砂轮磨削在加工机理上存在的主要区别，通过砂带干磨削和普通砂轮磨削的对比实验研究，证实了干磨法的可行性和优越性，认为砂带干磨削是未来制造领域中极有发展前途的切削加工新工艺。     

汽车铸件无模化数控成形快速制造技术的应用

介绍了基于模样的铸型制造工艺及设备、基于离散堆积原理的铸型无模制造、基于数控切削加工原理的铸型无模制造等3种铸型制作工艺及设备。开发了CAMTC-SMM1000铸型数控加工成形机,列举了无模化铸型数控加工在汽车发动机铸件砂型的快速制造、汽车覆盖件模具毛坯的快速制造上的应用,指出无模铸型的快速数字化制造方法是一种适于单件、小批量、多品种铸件的无模具生产技术,具有广阔的应用前景。     

模具数控磨削技术开发研究

研究了模具研腔的数控磨削加工技术,开发了安装于数控铣床主轴上的Ｔ／Ｄ牵引驱动增速装置和各种ＣＢＮ磨头,利用开发的增速器和ＣＢＮ磨头可进行平面、斜同、竖直面及空间自由曲面的磨削加工,为在ＮＣ机床和加工中心实现一次装夹完成模具的铣削和磨削加工提供了新的工艺装备和工艺条件。     

精密磨削Invar36合金时的磨料选择

本文对白刚玉、铬刚玉和绿色碳化硅三种磨料砂轮磨削Invar36合金时的磨削力、磨削温度、表面粗糙度和磨削比进行了对比分析。结果表明：白刚玉砂轮对Invar36合金的磨削比最高,磨削表面粗糙度较好,但是磨削温度和磨削力也比较高,适用于Invar36合金的粗磨;铬刚玉砂轮磨削时的磨削力最小,磨削温度最低,但是磨削比也比较低,因此适用于易变形零件的精密磨削。     

Fuzzy pattern recognition of AE signals for grinding burn

Grinding burn is a common phenomenon of thermal damage that has been one of the main constraints in grinding difficult-to-machine materials. Grinding burn damages materials and degrades properties, by causing tensile residual stresses or microfractures in the workpiece surface. Numerous methods have been proposed to identify grinding burn. However, the main problems of current methods are their sensitivity and robustness. This paper describes a new method of grinding burn identification with highly sensitive acoustic emission (AE) techniques. The wavelet packet transform is used to extract features from AE signals and fuzzy pattern recognition is employed for optimising features and identifying the grinding status. Experimental results show that the accuracy of grinding burn recognition is satisfactory.     

挤压油膜阻尼器在深孔磨削中的应用研究

基于挤压油膜阻尼理论，设计了带挤压油膜阻尼器（SFD）的深孔内圆磨削刀杆，并在高精度内圆磨床上进行了与静压支撑刀杆的磨削性能对比实验，实验表明，参数设计合理的SFD开杆较静压支撑刀杆具有更优良的磨削性能和减振效果，而且SFD刀杆较静压支撑刀杆结构简单，拆装方便，稳定性高，因此SFD在机械加工领域具有十分重要的研究价值和广泛的应用前景。     

Investigation of grinding modes in horizontal surface grinding of optical glass BK7

Grinding is one of the most important processes to manufacture hard-brittle materials such as optical glass. It is often desired to increase the material removal rate while maintaining the desired surface quality. The success of this approach relies on the better understanding of the relationship between the grinding modes and the characteristics of surface and subsurface integrities. Based on the kinematic analysis of horizontal surface grinding as well as the features of grinding-induced cracks, four grinding modes were proposed. They are brittle mode, semi-brittle mode, semi-ductile mode and ductile mode. The horizontal surface grinding of optical glass BK7 has been studied using diamond grinding wheel. The four different grinding modes have been investigated with the characteristics of surface morphologies before and after etching, surface roughness, subsurface damages as well as indentation depth. It was found that the level of surface roughness and depth of subsurface damage were strongly dependent on grinding mode. This study provides valuable insights into the material removal mechanism and the dependence of surface and subsurface integrities on grinding mode.     

磨削加工仿真预报系统的研究现状及发展趋势

磨削加工作为大部分产品成形前的最后一道工序,直接影响产品的加工精度和表面质量。磨削加工的多参数输入、输出和磨削过程中输入、输出参数之间的非线性映射决定了计算机仿真技术在磨削加工中应用的重要性。概述了计算机仿真技术相关理论,基于国内外磨削加工及预报模型,包括磨削运动学、磨削力、磨削温度、磨削液等模型的研究现状,对国内外将计算机仿真技术与磨削加工预报模型理论相结合的磨削加工仿真预报系统的研究现状进行了阐述。着重叙述了国内学者在磨削加工仿真预报系统软件开发方面的研究工作,最后展望磨削加工仿真预报系统的研究发展趋势。     

Experimental study on grinding force and grinding temperature of Aermet 100 steel in surface grinding

This paper investigates grinding force and grinding temperature of ultra-high strength steel Aermet 100 in conventional surface grinding using a single alumina wheel, a white alumina wheel and a cubic boron nitride wheel. First, mathematical models of grinding force and grinding temperature for three wheels were established. Then, the role of chip formation force and friction force in grinding force was investigated and thermal distribution in contact zone between workpiece and wheel was analyzed based on the mathematical model. The experimental result indicated that the minimum grinding force and the maximum grinding force ratio under the same grinding parameters can be achieved when using a CBN wheel and a single alumina wheel, respectively. When the phenomenon of large grinding force and high grinding temperature appeared, the workpiece material would adhere locally to the single alumina wheel. Grinding temperature was in a high state under the effect of two main aspects: poor thermal properties of grinding wheel and low coolant efficiency. The predicted value of grinding force and grinding temperature were compared with those experimentally obtained and the results show a reasonable agreement.     

磨削划伤成因分析与工程控制

磨削加工是现代装备制造业发展的重要支撑之一。但是，在磨削加工特别是精密、超精密磨削加工过程中，磨削划伤却时有发生，严重困扰着磨削技术的应用与发展。为此，通过大量磨削现场及零件表面磨削划伤查寻与测量，结合切削学、摩擦学、物理学、材料学、影像学相关知识，对磨削工程中各种磨削划伤进行了全面梳理及分析。探究了磨削划伤的主要技术特征；基于砂轮周边磨削和端面研磨二种磨削方式，揭示了单颗磨粒磨削划伤和团聚磨粒磨削划伤形成过程；归纳了影响磨削划伤的主要因素，提出了应对技术措施。     

Diamond-Bronze Coatings for Grinding Applications

Grinding applications for the machining of stone and concrete require composite tools where large diamonds are perfectly embedded into a metallic matrix. With the detonation flame spraying process, it is possible to manufacture these super abrasive composites. Excellent embedment of the voluminous super abrasive particles into the matrix coating material can be realized to produce high quality composite layers for grinding applications of stone and concrete. In this paper, different diamond gradings as well as different volume contents of diamond in matrix are compared. Especially, the influence of particle size on its implantation efficiency is investigated and the influence of process and substrate temperature is analyzed. The thermal sprayed grinding tools are evaluated with respect to their microstructure as well as their grinding abilities. Compared to sintered diamond-bronze samples, the results of an adaptively designed grinding test for the machining of concrete are presented and analyzed.     

不同晶粒度硬质合金的磨削性能研究

本文通过磨削试验,从磨削功率、磨削比、磨削表面光洁度等方面研究了粗晶、细晶、超细晶粒三种含Co量相同的K类硬质合金的磨削性能。研究结果表明,上述三种硬质合金在各磨削参数相同的情况下,所消耗的磨削力、磨削能随硬质合金晶粒尺寸的增加而增大。同一砂轮对上述硬质合金的磨削比随晶粒尺寸的增加而增大。在磨料粒度与硬质合金粒度相当时,所加工表面的月。值随WC晶粒度的变粗而变差．