液体磁性磨具光整加工机理研究

液体磁性磨具在无外磁场作用下时表现出良好的流体特性;但在强磁场的作用下在毫秒级的时间内增加两个数量级以上,表现出类似固体的特性,这种特性称为液体磁性磨具的流变性.利用这种流变性实现光整加工的方法称为液体磁性磨具光整加工法.研究了液体磁性磨具微观结构后,对其加工机理进行了分析.     

液体磁性磨具光整加工的参数选择

液体磁性磨具光整加工技术是用磨具本身的流变特性对工件表面进行光整加工的新技术.在实际加工试验研究的基础上,分析了磁场强度、工件转速、加工时间工艺参数对加工表面质量的影响规律;为进一步研究液体磁性磨具的加工机理和加工装置的改进提供了依据.     

纳米二氧化硅对液体磁性磨具稳定性改良的研究

液体磁性磨具是将最新的智能材料技术、磁流变技术应用于光整加工过程,但其稳定性大大阻碍了液体磁性磨具光整加工的实用化进程.因此文章主要研究液体磁性磨具中加入纳米级的二氧化硅对其沉降稳定性的影响.并就纳米二氧化硅对相变结构的影响机理进行分析.     

粘弹性磁性磨具对铝板平面的光整加工研究

介绍了一种新型的磁性磨料—粘弹性磁性磨具,该磨具制备工艺相对简单,使用方便且光整性能可靠,并概述了其工作原理及影响磨具最终光整效果的主要因素。通过所制粘弹性磁性磨具对铝板平面的光整加工实验,分析了磁极头旋转速度及光整加工工作间隙对磨具光整性能的影响。采用工艺优化的方案,提升了粘弹性磁性磨具的光整效率,经25min光整加工后,试件表面的Ra值可降低到0.121μm。粘弹性磁性磨具为磁性磨料制备的新思路,具有广阔的应用前景。     

液体磁性磨具光整加工TC4钛合金的试验研究

为解决TC4钛合金材料难加工问题,采用液体磁性磨具对TC4钛合金进行了表面加工试验。通过调整工艺参数,采用田口方法对TC4钛合金液体磁性磨具光整加工的工艺参数进行优化。采用单因素试验法,研究磨料类型、磨料粒径、工件转速和电流强度等工艺参数对液体磁性磨具光整加工TC4钛合金材料加工性能的影响,并总结各工艺参数对工件表面粗糙度的影响规律。根据信噪比的望大特性分析得出,在液体磁性磨具光整加工TC4钛合金材料的加工过程中,当使用2 000目的白刚玉,主轴转速为500 r/min,电流强度为1.5 A加工时,工件表面粗糙度相对下降率%ΔRa达到了86.10%。液体磁性磨具光整加工TC4材料表面的最优工艺参数组合为:2 000目的白刚玉,主轴转速为700 r/min,电流强度为2.0 A。同时得出各工艺参数对工件表面粗糙度相对下降率%ΔRa的影响大小依次为:磨料类型磨料粒径工件转速电流强度。当采用2 000目的白刚玉配置的磨料进行加工时,工件的表面粗糙度Ra达到了0.096μm。采用液体磁性磨具光整加工技术可以有效地降低TC4钛合金材料的表面粗糙度和提升其工件表面加工质量,显著改善了传统加工方式中存在的烧蚀和烧伤现象。     

液体磁性磨具光整加工的流体动力学模型研究

液体磁性磨具是利用磁致相变原理研制的新型光整用具。参考了国内外相关研究之后,建立了液体磁性磨具光整加工的流体动力学数学模型,并用有限元分析软件ANSYS中的CFD模块-FLOTRAN,对液体磁性磨具加工中的流场（速度场）和剪切应力进行了数值模拟,该结果与理论模型取得了较好的一致。     

聚乙二醇对液体磁性磨具稳定性的影响研究

稳定性是评价液体磁性磨具性能的重要指标之一,其对液体磁性磨具在机械光整加工领域的商业应用与推广有着重要影响。为提高液体磁性磨具稳定性,依据液体磁性磨具中固相颗粒表面特性,提出了利用聚乙二醇(PEG)改性的方法。通过以聚乙二醇(PEG)添加量作为控制变量进行实验分析,发现聚乙二醇(PEG)的添加量对磨具稳定性有显著影响,并从微观角度讨论了聚乙二醇(PEG)添加量对固相颗粒间相互作用力的影响规律。研究成果对液体磁性磨具的配制具有一定的指导和借鉴意义。     

液体磁性磨具滑移效应对材料去除率的影响

滑移效应对液体磁性磨具孔光整加工的材料去除率有重要影响,它可能导致磁场强度较高区域的工件表面材料去除率较低,进而导致加工不一致,甚至导致加工堵塞,阻碍加工的进行,缩短设备的寿命。通过理论分析,建立了滑移模型及材料去除率模型。得到了滑移效应对材料去除率的影响规律:液体磁性磨具孔光整加工存在有效磁场强度区间;在该区间内,材料去除率随磁场强度的增大而增大;在该区间外,加工效率极低或不能进行加工。设计实验验证了所得结论。提出通过选用适当磁场并旋转工件角度的优化方法来达到较好加工效果的工艺改进。研究对液体磁性磨具孔光整加工技术的理论分析和工艺改进有较大意义。     

液体磁性磨具小孔光整加工的机理分析及实验研究

针对发动机上喷油孔、高压油管等小孔内壁光整加工困难的问题,设计了一种适用于小孔内壁光整加工的新装置。阐述了液体磁性磨具对小孔内壁光整加工的机理,在此基础上分析了影响材料去除率的因素,并且通过实验验证了入口压力、外加电流强度(即磁场强度)、加工时间等因素对加工效率以及加工后小孔内壁最终表面粗糙度的影响,从而得出了优化的小孔内圆表面光整加工参数,对实施其他小孔内圆表面的光整加工有一定的指导和借鉴作用。     

纳米磁性液体材料在光整加工中的应用研究

磁性液体材料是一种特殊的新型材料,是由磁性纳米微粒(一般要求小于10 nm)均匀弥散于某种液体基液中所构成的稳定体系.磁性液体光整加工是利用磁性液体的流动性和磁性来保持磨料与工件之间产生相对运动,从而达到光整工件的精加工方法.根据磁性液体的典型特性,研究了用于磁性液体光整加工的磨削机理,阐述了磁性液体光整加工特点,介绍了实现磁性液体光整加工的方法.     

磁性研磨在模具曲面抛光中的应用

针对大型模具曲面精整加工的问题,探讨采用磁性研磨加工模具曲面的工艺。根据磁性研磨加工原理,基于数控铣床研制了磁性研磨实验装置,采用工具旋转的磁性研磨加工方式,磁性磨料受到磁场约束力和离心力的作用,成为影响加工过程正反两方面的因素。对模具曲面进行磁性研磨加工实验,针对模具曲面研磨量不均匀问题,分析了影响曲面研磨量的主要因素,提出了从磁极形状和研磨轨迹等方面控制研磨量的方法。     

球形磁性磨料磁力研磨ZrO2材料机理研究

在磁力研磨加工ZrO 2材料过程中,分析了单颗磁性磨料在加工区域内的受力情况,并对研磨压力的形成进行探讨,利用公式推导计算研磨压力,通过研磨压力的大小分析了磁力光整加工中材料的去除机理,包括脆性断裂去除、塑性变形去除和粉末化去除。通过白光干涉仪、扫描电子显微镜等分析检测仪器对磁力研磨加工后的工件表面进行检测,可知在其他条件相同时,磁力研磨加工后的工件材料精度高于传统的草轮抛光精度,可达到0.59μm。     

Modeling and simulation of magnetic abrasive finishing process

Magnetic abrasive finishing (MAF) is one of the advanced finishing processes, which produces a high level of surface quality and is primarily controlled by a magnetic field. In MAF, the workpiece is kept between the two poles of a magnet. The working gap between the workpiece and the magnet is filled with magnetic abrasive particles. A magnetic abrasive flexible brush (MAFB) is formed, acting as a multipoint cutting tool, due to the effect of the magnetic field in the working gap. This paper deals with the theoretical investigations of the MAF process. A finite element model of the process is developed to evaluate the distribution of magnetic forces on the workpiece surface. The MAF process removes a very small amount of material by indentation and rotation of magnetic abrasive particles in the circular tracks. A theoretical model for material removal and surface roughness is also proposed accounting for microcutting by considering a uniform surface profile without statistical distribution. Numerical experiments are carried out by providing different routes of intermittent motion to the tool. The simulation results are verified by comparing them with the experimental results available in the literature.     

Modeling and simulation of magnetic abrasive finishing process

Magnetic abrasive finishing (MAF) is one of the advanced finishing processes, which produces a high level of surface quality and is primarily controlled by a magnetic field. In MAF, the workpiece is kept between the two poles of a magnet. The working gap between the workpiece and the magnet is filled with magnetic abrasive particles. A magnetic abrasive flexible brush (MAFB) is formed, acting as a multipoint cutting tool, due to the effect of the magnetic field in the working gap. This paper deals with the theoretical investigations of the MAF process. A finite element model of the process is developed to evaluate the distribution of magnetic forces on the workpiece surface. The MAF process removes a very small amount of material by indentation and rotation of magnetic abrasive particles in the circular tracks. A theoretical model for material removal and surface roughness is also proposed accounting for microcutting by considering a uniform surface profile without statistical distribution. Numerical experiments are carried out by providing different routes of intermittent motion to the tool. The simulation results are verified by comparing them with the experimental results available in the literature.     

新型的复杂曲面磁粒光整加工机床

介绍了一种复杂曲面光整加工机械--三坐标数字化磁粒光整加工机床.该机床通过对复杂曲面的数字化测量和自动编程,得到磁极与工件保持一定间隙沿工件表面运行的加工轨迹,利用吸附在工具磁极上面的磁性磨料为工具,通过磁极带动磁粒沿工件表面作高速旋转,从而实施对工件表面的光整加工.该机床的研制成功实现了复杂曲面光整加工的自动化.     

一种基于气压悬浮磨料池光整加工方法的研究

针对复杂曲面难加工零件,提出一种基于气压悬浮磨料池光整加工方法:采用气压悬浮磨料的混合方式,工件表面与流态化磨料产生相对运动速度,从而使固体颗粒与工件表面发生微观二体磨料磨损.通过对磨粒进行动力分析以及气固二相流加工机理分析,揭示了磨料池内部气体和磨料混合及扩散规律.利用光整加工实验确定了光整加工过程中最佳的主轴转速和...     

Study of an internal magnetic abrasive finishing using a pole rotation system: Discussion of the characteristic abrasive behavior

An internal magnetic abrasive finishing process using a pole rotation system was proposed to produce highly finished inner surfaces of workpieces used in critical applications. Previous research found that the process incorporating one of the characteristic behaviors of the abrasive, the jumbling of the abrasive, results in aggressive contact of the abrasive against the inner surface, disturbing the smooth surface finish. The aim of this paper, therefore, is to characterize the in-process abrasive behavior against the surface and its effects on the finishing characteristics and to describe the finishing mechanism. The magnetic force acting on the magnetic abrasive, controlled by the field at the finishing area, is considered the primary influence on the abrasive behavior against the inner surface of the workpiece. This study examines the relationships between the magnetic field, the force on the abrasive, and the abrasive behavior. The surface roughness and material removal measurements resulting from finishing experiments demonstrate the effects of the abrasive behavior on the surface modifications. This paper also proposes a method to monitor the in-process abrasive behavior to facilitate processing.     

自由曲面数字化磁性磨粒光整加工机床

介绍一种自由曲面数字化磁性磨粒光整加工机床,着重介绍其原理、结构、组成、工具、磁性磨料、曲面数字化测量和编程方法。该机床通过对模具曲面的数字化测量和自动编程,得到磁极与工件保持一定间隙沿工件表面运行的加工轨迹,利用吸在工具磁极上的磁性磨料为工具,通过磁极带动磁性磨粒作高速旋转,实现工件自由曲面光整加工的自动化。     

外圆表面磁性研磨加工的研究

以加工外圆表面为例，分析对影响磁性研磨这一种新的表面光整加工工艺中的和种工艺参数进行佤分析，探求外圆表面磁性研磨加工的最佳工艺参数。     

Development and Polishing Process of a Mobile Robot Finishing Large Mold Surface

□ A novel self-determination polishing robot finishing large mold free-form surface is developed, and the finishing process method is researched. Contrary to traditional approaches, our premise is that a large mold surface can be polished by using a small robot. This robot system is mainly composed of a polishing robot part, a computer system and a visual positioning system. A type of robot with four uniform distribution wheels was designed, which has two driving wheels and two driven wheels. Active compliant control of the polishing tool was provided by a pneumatic servo system, and a new special compliant abrasive tool was proposed on the basis of robot characteristics. The process planning steps consisted of subdividing the free-form surface, choosing an abrasive tool, planning the polishing path and optimizing machining parameters. Based on the orthogonal experiment and the grey relational analysis method, the optimal parameter combination was obtained for polishing force, tool speed and feed rate. Aiming to polishing times, the surface roughness method and polishing efficiency method were studied in detail. The polishing experiments were carried out in the robot using process parameters obtained by the efficiency method. These research results provided significant theory foundation and experimental data for a mobile robot planning polishing to realize intelligible process parameter selection.