Grinding/Cutting Technology and Equipment of Multi-scale Casting Parts

Multi-scale casting parts are important components of high-end equipment used in the aerospace,automobile manufacturing,shipbuilding,and other industries.Residual features such as parting lines and pouring risers that inevitably appear during the casting process are random in size,morphology,and distribution.The traditional manual processing method has disadvantages such as low efficiency,high labor intensity,and harsh working environment.Existing machine tool and serial robot grinding/cutting equipment do not easily achieve high-quality and high-efficiency removal of residual features due to poor dexterity and low stiffness,respectively.To address these problems,a five-degree-of-freedom(5-DoF)hybrid grinding/cutting robot with high dexterity and high stiffness is proposed.Based on it,three types of grinding/cutting equipment combined with offline programming,master-slave control,and other technologies are developed to remove the residual features of small,medium,and large casting parts.Finally,the advantages of teleoperation processing and other solutions are elaborated,and the difficulties and challenges are discussed.This paper reviews the grinding/cutting technology and equipment of casting parts and provides a reference for the research on the processing of multi-scale casting parts.

Tribological Approach and Surface Quality Analysis of Stainless Steel for Cutlery Applications after Surface Grinding

In precision machining processes such as grinding,for example,analysis of machined surface is important one of most parameters to evaluate process performance.Equally important is to perform tribological analysis to understand chip formation and abrasive wheel wear,thus enabling manufacturing of components free of thermal damages.In grinding,due to high hardness of abrasive grains that remove material from workpiece in chip form and very low values of radial depth of cut,combination of low roughness values and tight dimensional tolerances is attained.Accordingly,the parameters involved in this process are determinant in surface quality that is primarily evaluated in terms of surface roughness and workpiece functionality.In this work,surface roughness(Rt parameter)and scanning electron microscope(SEM)images of ground surfaces of the AISI 420 martensitic stainless steel samples were evaluated.Tests were carried out in surface grinding with a white aluminum oxide wheel and an environmentally-friendly semisynthetic water-soluble coolant.Two values of radial depth of cut(10μm and 25μm)were tested.The results showed that the highest roughness values,deeper grooves on the machined surfaces as well as poorer surface quality were obtained after grinding under the severest cutting conditions.

Comprehensive modeling approach of axial ultrasonic vibration grinding force

The theoretical model of axial ultrasonic vibration grinding force is built on the basis of a mathematical model of cutting deforming force deduced from the assumptions of thickness of the undeformed debris under Rayleigh distribution and a mathematical model of friction based on the theoretical analysis of relative sliding velocity of abrasive and workpiece. Then, the coefficients of the ultrasonic vibration grinding force model are calculated through analysis of nonlinear regression of the theoretical model by using MATLAB, and the law of influence of grinding depth, workpiece speed, frequency and amplitude of the mill on the grinding force is summarized after applying the model to analyze the ultrasonic grinding force. The result of the above-mentioned law shows that the grinding force decreases as frequency and amplitude increase, while increases as grinding depth and workpiece speed increase; the maximum relative error of prediction and experimental values of the normal grinding force is 11.47% and its average relative error is 5.41%; the maximum relative error of the tangential grinding force is 10.14% and its average relative error is 4.29%. The result of employing regression equation to predict ultrasonic grinding force approximates to the experimental data, therefore the accuracy and reliability of the model is verified.

Investigation of Creep Feed Grinding Parameters and Heat treatment Effects on the Nickel-base Superalloys

The Nickel base Superalloys are the most famous complicated and useable of Superalloys to make hot zone components of the gas turbines. The complicated dimensional tolerances, specially at the root of the blade show importance of grinding processes at the production of blades root. The prediction of the effect of machining parameters on the soundness of component surface strengthening for reaching to a suitable surface finishing and avoiding from crack formation at the work part during machining operation often is not easy and feasible so needs to more industrial investigation. This research is about frame 5 blade designed by GE and made from Superalloy IN738LC has been investigated. The formation of a plastically deformed and heat affected zone during grinding of Superalloy IN738LC with a high depth of cut but slow work speed (creep feed grinding) was investigated. Parameters such as work speed, depth of cut and radial dressing speed have been considered as variables and their effects have been studied. During experimental performed, the voltage and current of motor measured and power and special energy calculated. Some samples heat-treated (of the 1176°C for 1 hr under neutral argon gas and cooling rate of 15°C /min up to 537°C and then air cooling) to study grains recrystallization. Other samples have been created from the roots of blades and then coated by Nickel to measure boundary layer micro-hardness. The results show that increasing work speed leads to increasing the use power. Increasing the depth of cut, by increasing material removal rate, and the radial dressing speed, by decreasing power, lead to decreasing special energy. The temperature created by grinding lead to decreasing plastic deformation and boundary layer formation. When the radial dressing speed changes from 1 to 0.6 u,m/rev and other parameters are kept unchanged the roughness of surface increases and the special energy decreases. Sufficient dressing is very essential in limiting the width of the molten zone to few micrometers. As a result, it was found that local melting at contact spots to be a rather common mechanism during grinding of superalloys, lead to so-called white layers which can easily be observed on metallographic cross sections.

Experimental Evaluation on Grinding Texture on Flank Face in Chamfer Milling of Stainless Steel

The surface quality of chamfer milling of stainless steel is closed related to the products of 3 C(Computer, Communication and Consumer electronics), where a cutter is a major part to achieve that. Targeting a high-quality cutter,an experimental evaluation is carried out on the influence of grinding texture of cutter flank face on surface quality.The mathematic models of chamfer cutter are established, and they are validated by a numerical simulation. Also the grinding data are generated by the models and tested by a grinding simulation for safety reasons. Then, a set of chamfer cutting tools are machined in a five-axis CNC grinding machine, and consist of five angles between the cutting edge and the grinding texture on the 1 st flank faces, i.e., 0°, 15°, 30°, 45° and 60°. Furthermore, the machined cutting tools are tested in a series of milling experiments of chamfer hole of stainless steel, where cutting forces and surface morphologies are measured and observed. The results show that the best state of both surface quality and cutting force is archived by the tool with 45° grinding texture, which can provide a support for manufacturing of cutting tool used in chamfer milling.

Applications of High-Efficiency Abrasive Process with CBN Grinding Wheel

High-efficiency abrasive process with CBN grinding wheel is one of the important techniques of advanced manufacture. Combined with raw and finishing machining, it can attain high material removal rate like turning, milling and planning. The difficult-to-grinding materials can also be ground by means of this method with high performance. In the present paper, development status and latest progresses on high-efficiency abrasive machining technologies with CBN grinding wheel relate to high speed and super-high speed grinding, quick point-grinding, high efficiency deep-cut grinding, creep feed deep grinding, heavy-duty snagging and abrasive belt grinding were summarized. The efficiency and parameters range of these abrasive machining processes were compared. The key technologies of high efficiency abrasive machining, including grinding wheel, spindle and bearing, grinder, coolant supplying, installation and orientation of wheel and workpiece and safety defended, as well as intelligent monitor and NC grinding were investigated. It is concluded that high efficiency abrasive machining is a promising technology in the future.

弹性磨抛轮加工硅片面形预测模型及试验验证

目的为分析弹性磨抛轮磨削硅片面形精度变化的影响因素,优化加工参数以获得良好的磨削面形。方法通过建立考虑弹性磨抛轮转速、硅片转速、偏心距等参数的弹性磨抛轮磨粒运动轨迹模型,结合单颗磨粒切削深度,提出了弹性磨抛轮加工硅片的材料去除非均匀性预测方法,建立了基于弹性磨抛轮磨削硅片的面形预测模型,并通过不同转速比下的磨削试验验证了预测模型的准确性。结果面形预测模型仿真出的面形与弹性磨抛轮加工试验后的硅片面形一致,均呈“凸”形,且PV值随转速比的增大而增大。转速比为1时,磨削后硅片面形PV值为0.54μm,仿真模型计算出的PV值为0.49μm,转速比为5时,磨削后硅片面形PV值为2.12μm,仿真模型计算出的PV值为2.38μm。结论磨削试验面形PV值与模型计算面形PV值的预测误差小于13%,建立的面形预测模型能够成功预测硅片的面形规律,可以分析加工参数对硅片面形的影响规律。由面形预测模型分析可知,转速比对硅片面形精度有影响,且随着转速比的增加,硅片面形不断恶化,因此在实际加工中,应选择较小的转速比进行加工,以获得更优的硅片面形精度。

单颗CBN磨粒超声振动辅助磨削AISI 304材料去除机理

为了解释超声作用下磨粒切削材料的去除机理,对单粒磨削过程进行了分析,建立了未变形切削厚度和磨粒与试件的固定速度比(vs/vw)的数学模型.在AISI 304试件上进行了固定速度比的普通磨削(conventional grinding,CG)、切向超声振动辅助磨削(tangential ultrasonic vibration assisted grinding,TUVAG)以及径向超声振动辅助磨削(radial ultrasonic vibration assisted grinding,RUVAG)的单颗粒试验.结果表明,在固定速度比条件下,试件在CG与TUVAG作用下都是以塑性变形的形式去除,但超声辅助显著提高了材料去除率.试件在RUVAG作用下材料的去除方式与未变形切削最大厚度agmax的值息息相关.agmax小于0.8μm时,试件表现为脆性断裂的形式去除;之后随着agmax逐渐增大,试件转变为塑性变形的形式去除.

高速机械粉磨对油基钻屑灰渣活性的影响

对油基钻屑灰渣进行了高速机械粉磨处理,研究了粉磨时间(0~7 min)对灰渣粒径分布和比表面积的影响,分析了掺灰渣胶砂试件的力学性能,并进行了XRD、SEM、FTIR微观分析。结果表明:与未粉磨处理的灰渣相比,粉磨3 min灰渣的粒径分布范围缩小至1.220~40.100μm,D50降低了60.9%,比表面积增大了27.6%;与其他粉磨时间的灰渣相比,用粉磨3 min的灰渣等质量取代30%水泥所制备的胶砂试件的28 d抗压强度最高,28 d抗折强度也较高;适宜的粉磨时间能够促进灰渣中的活性Si O2、Al2O3等与水泥水化产物Ca(OH)2发生二次水化反应,生成C-S-H凝胶和AFt,提高胶砂结构的密实度。

动脉血管钙化斑块旋磨研究综述

旋磨术是治疗血管钙化病变的一种微创技术,通过微型砂轮去除堵塞在血管内的钙化斑块组织,达到疏通血管、重建血液流动的目的。钙化斑块组织堵塞血管造成供血不足,易诱发多种心血管疾病,其硬度较大导致球囊和支架无法撑开,目前临床上普遍采用旋磨术进行疏通。首先综述了旋磨术的相关研究成果和发展趋势,并对旋磨器械发展进行了介绍;其次总结了旋磨术优劣势的相关内容;然后对旋磨机理进行了详细的分析;最后总结了旋磨术目前存在的不足与未来的研究方向。

液晶玻璃基板后加工玻璃粉(ADG)产生及管理措施

本论文主要探讨了液晶玻璃基板在冷端后加工过程中产生的玻璃粉问题及其有效治理方法。液晶玻璃基板作为平板显示产业的关键基础材料,在切割、掰断、研磨等加工环节中,不可避免地会产生一定量的微细玻璃粉颗粒,这些玻璃粉不仅影响生产环境和设备寿命,更重要对基板品质造成影响,导致良品率降低。通过详细分析液晶玻璃基板后加工过程中玻璃粉产生的机理,包括切割、掰断、研磨三个工序玻璃粉产生原因,提出了系统的玻璃粉治理策略。从刀轮选型、切割质量、掰断工艺、研磨工艺等方面着手,降低玻璃粉发生率,减少玻璃粉污染,从本质上提升液晶玻璃基板后加工环节玻璃粉治理。

蓝宝石切割研磨及抛光技术研究进展

蓝宝石晶体由于其高硬度、良好的化学、光学特性,被广泛应用于许多领域。但蓝宝石晶体本身的高硬度、高脆性和高耐蚀性,使其切割、研磨及抛光难度增加。本文介绍了蓝宝石加工技术的研究进展,探讨了蓝宝石加工过程中存在的问题,分析了提高蓝宝石切割、研磨和抛光技术的工艺措施,提出了蓝宝石切割研磨和抛光技术的发展方向。

刀剪机器人开刃砂轮修整补偿系统

针对目前刀剪开刃生产效率低、质量不稳定等问题,根据机器人开刃工艺特点,设计刀剪机器人开刃砂轮修整补偿系统。介绍了这一系统的工作原理,分析了机械机构。通过数控系统进行砂轮磨损自动修整,利用数据传输与机器人控制实现数据同步,达到砂轮修整值与机械臂补偿值一致。试验结果表明,刀剪机器人开刃砂轮修整补偿系统以修整砂轮代替补偿砂轮,解决以往砂轮磨损补偿方法的不足,能够可靠保证机器人连续开刃精度的一致性,有效提高生产效率。

双马来酰亚胺树脂(BMI)在超薄树脂切割砂轮中的应用研究

文章以改性酚醛树脂(PF)、双马来酰亚胺(BMI)、改性酚醛树脂(PF)与双马来酰亚胺(BMI)共混树脂作为研究对象,对三种树脂的性能及其在超薄树脂切割砂轮中应用进行了系统对比分析。结果表明:PF在耐热性、力学性能方面优于BMI;PF应用于超薄砂轮在QFN材料切割寿命方面优于BMI;BMI应用于超薄砂轮在Al2O3材料切割质量方面优于PF;PF改性BMI可提高超薄树脂切割砂轮成型精度。

一种激光切割打磨装置

介绍一种激光切割打磨装置,可用于商用车U型纵梁切割加工时的打磨除渣。本装置由固定打磨机构、活动打磨机构、气动系统、控制系统等组成。本设计对现有技术中存在的不足,提供了一种结构简单、操作方便且性能稳定的激光切割打磨装置。

PCBN刀具以车代磨加工20CrMnTi合金钢试验研究

采用聚晶立方氮化硼(PCBN)刀具,以车代磨对20CrMnTi合金钢进行精密切削加工。分析了切削过程中PCBN刀具的磨损形式和磨损机理,研究了不同切削参数对刀具寿命与工件表面粗糙度的影响。结果表明,切削过程中刀具发生了扩散、崩刃以及氧化磨损;在硬态切削三要素中,切削进给量和切削速度对刀具磨损量影响较大,切削进给量对工件表面粗糙度影响较大。

高效复合材料结构件倒角曲面加工方法及工具研制

为了解决复合材料结构件边缘倒角曲面加工效率低和质量差的问题,需要进行复合材料边缘倒角曲面精准加工技术研究,研制出高效复合材料结构件边缘倒角曲面精准加工的方法及工具。通过系统的加工试验优化复合材料边缘倒角曲面精准加工工具的结构及其结构参数、加工参数,并证明了此方案的有效性。

硬质合金整体刀具外圆磨削加工表面缺陷分析

亚微、超细和纳米晶硬质合金是硬质合金整体刀具的典型材质,磨削加工表面缺陷会严重影响其使用寿命和服役行为的稳定性。本文分析了硬质合金整体刀具外圆磨削加工表面存在的4种典型缺陷及其形成原因,即磨屑表面粘附、表面条状撕裂、黏结相浸出和次表层裸露、WC晶粒碎裂。剖析了硬质合金整体刀具磨削加工的特殊性,即(1)合金中易存在以Co池和WC晶粒异常长大为典型代表的微观缺陷;(2)高矫顽磁力导致的难消磁特性;(3)高硬度和高强度导致的磨削碎屑的强损伤力;(4)低热导率和强磨削力工况条件对磨削液施载效果的严要求;(5)微观缺陷与磨削液的交互作用可促进黏结相和硬质相的电偶腐蚀和磨削表面Co的浸出;(6)强磨削力和WC本征脆性共同作用下,WC微小碎粒的形成对高效排屑的严要求。在棒材材质质量控制、磨削加工、磨屑处置、加工工序、磨削液选择与使用、磨削后处理和产品包装等方面提出了一系列抑制与预防磨削加工表面缺陷的建议。

玉米淀粉树脂基砂轮片的制备与表征

以淀粉、糠醛与甲醛共缩聚合成淀粉基树脂为基质,二氧化硅颗粒为研磨材料制备新型天然可再生生物质砂轮片,分析了淀粉基树脂的主要化学结构、黏度和凝胶时间及砂轮片的微观形态和力学性能。结果表明:淀粉、糠醛与甲醛在弱酸性条件下发生了共缩聚反应,该淀粉基树脂的玻璃化转变温度较纯淀粉树脂高。用该树脂制备的砂轮片的硬度高于自制酚醛树脂砂轮片,且该生物质树脂基砂轮片的切割性能与自制酚醛树脂砂轮片相近。因此,未来用该砂轮片替代部分酚醛树脂基砂轮片是可行的。

基于切削加工性能的螺杆转子成形砂轮安装参数二次优化设计方法

传统的螺杆转子成形砂轮设计研究主要集中在成形砂轮廓形精度提升方面,成形砂轮的切削加工性能与成形砂轮安装参数之间的耦合关系没有得到足够的关注,导致设计出来的螺杆转子成形砂轮切削加工性能不高,从而致使螺杆转子的成形磨削表面质量差、加工效率低。本文提出了一种新的基于切削加工性能的螺杆转子成形砂轮安装参数二次优化设计方法。首先,基于空间啮合原理设计螺杆转子成形砂轮安装参数优化设计程序,获得不干涉条件下的螺杆转子成形砂轮安装参数范围;其次,对不同安装参数下成形砂轮与螺杆型面的接触特性,以及不同安装参数条件下成形砂轮的轮廓特性、切削加工特性进行系统的分析和研究,获得了螺杆转子成形砂轮安装参数选择策略。以某型号三螺杆泵阳转子为例对该方法进行验证,结果表明,在保证加工质量的前提下,该方法可以显著降低螺杆转子精密磨削成本,具有较好的理论创新性与工程应用价值。