On going trend of miniaturization in electronic rel at ed parts, which is an average of two times in every 5～7 years introduce grindin g challenges. In grinding process, the surface waviness control of thin parts is ...On going trend of miniaturization in electronic rel at ed parts, which is an average of two times in every 5～7 years introduce grindin g challenges. In grinding process, the surface waviness control of thin parts is an ardent task due to its warpage, induced by the high specific grinding energy (2～10 J/mm 3). Therefore, coolant is often used to avoid thermal damage, obtai n better surface integrity and to prolong wheel life. However coolant, the incomp ressibility media introduce high forces at the grinding zone creating dimensiona l as well as shape instability. In view of these situations chilled air was ap plied in place of conventional coolant. The chilled air is produced using a two -stage vapor compression refrigeration cycle with characteristics of: temperatu re -35 ℃, pressure 0.2～0.3 MPa and flow rate 0.4 m 3/min. Also traces of eco - oil mist that encompass the chilled air are supplied to the grinding zone. B oth chilled air and eco-oil mist are applied through two independent paths of a specially designed twin compartment nozzle for maximizing the penetration. This paper investigates the grinding characteristics of mold insert which is closer to M2 tool steel (component widely used in connector industries) when using chil led air as coolant media. Grinding experiments were conducted using a vitrified bond CBN wheel (B91N100V) and a surface grinder. Initial study was focussed on establishing the most suita ble clamping method for the thin mold insert. FEM analysis and grinding experime nt studies were performed to quantitatively analyze the clamping induced deflect ion. Waviness value (W t) of (24～62) μm was achieved for resin clampi n g whereas (4～8) μm, (4～6) μm were achieved for magnetic and wax clamping res pe ctively. Wax clamping is predominantly used in all the grinding experiments that characterize the grinding process, which use chilled air as the coolant media. Between 0.15 to 0.9 mm 3/mm.s of specific material removal rate, ground sur face temperature of mold insert was increased from 0.3 ℃ to 59.7 ℃ for chi lled air. For the similar grinding conditions with the coolant fluid an increase from 0.9 ℃ to 14.4 ℃ was recorded. With increase of specific material removal rate from 0.15 to 0.65 mm 3/mm.s, F t/F n ratio was increased from (0.2 to 0.4), (0.6 to 1.67) for wet coolant and chilled air respectively. Despite of high F t/F n ratio and ground surface temperature, chilled air method has shown a surface waviness, W t from (2 to 5.6) μm. Microstructure examination of chilled air produced ground surface was comparable to those of using coolant fluids. Surface finish, R a of (0.45～0.7) μm was achieved for mold insert . This work will enable to have clear understanding about the quantitative influe nce of chilled air as well as the clamping method against the surface waviness o f thin mold insert.展开更多
Put forward a new kind of polishing method,ultrasonic magnetic abrasive fin-ishing(UMAF),and studied its mechanism of improving polishing efficiency.By analyzingall kind of forces acting on single abrasive particle in...Put forward a new kind of polishing method,ultrasonic magnetic abrasive fin-ishing(UMAF),and studied its mechanism of improving polishing efficiency.By analyzingall kind of forces acting on single abrasive particle in the polishing process and calculatingthe Size of the composition of forces,get the conclusion that UMAF will enhance the effi-ciency of the normal magnetic abrasive finishing(MAF)due to the ultrasonic vibration in-creases the cutting force and depth.At last the idea of designing the UMAF system basedon numerical control milling machine is put forward which is convenient to setup and willaccelerate the practical application of MAF.展开更多
Through theoretical and experimental researeh about automatic polishing on thecurved surfaces of the moulds, the limitation of the polishing method at constant pressure, whichis adopted widely in the world, is analyse...Through theoretical and experimental researeh about automatic polishing on thecurved surfaces of the moulds, the limitation of the polishing method at constant pressure, whichis adopted widely in the world, is analysed. Based on the analysis, a new polishing method atconstant pressure intensity is proposed, and the corresponding goveming equation and a com-prehensive polishing parameter are given as well.展开更多
文摘On going trend of miniaturization in electronic rel at ed parts, which is an average of two times in every 5～7 years introduce grindin g challenges. In grinding process, the surface waviness control of thin parts is an ardent task due to its warpage, induced by the high specific grinding energy (2～10 J/mm 3). Therefore, coolant is often used to avoid thermal damage, obtai n better surface integrity and to prolong wheel life. However coolant, the incomp ressibility media introduce high forces at the grinding zone creating dimensiona l as well as shape instability. In view of these situations chilled air was ap plied in place of conventional coolant. The chilled air is produced using a two -stage vapor compression refrigeration cycle with characteristics of: temperatu re -35 ℃, pressure 0.2～0.3 MPa and flow rate 0.4 m 3/min. Also traces of eco - oil mist that encompass the chilled air are supplied to the grinding zone. B oth chilled air and eco-oil mist are applied through two independent paths of a specially designed twin compartment nozzle for maximizing the penetration. This paper investigates the grinding characteristics of mold insert which is closer to M2 tool steel (component widely used in connector industries) when using chil led air as coolant media. Grinding experiments were conducted using a vitrified bond CBN wheel (B91N100V) and a surface grinder. Initial study was focussed on establishing the most suita ble clamping method for the thin mold insert. FEM analysis and grinding experime nt studies were performed to quantitatively analyze the clamping induced deflect ion. Waviness value (W t) of (24～62) μm was achieved for resin clampi n g whereas (4～8) μm, (4～6) μm were achieved for magnetic and wax clamping res pe ctively. Wax clamping is predominantly used in all the grinding experiments that characterize the grinding process, which use chilled air as the coolant media. Between 0.15 to 0.9 mm 3/mm.s of specific material removal rate, ground sur face temperature of mold insert was increased from 0.3 ℃ to 59.7 ℃ for chi lled air. For the similar grinding conditions with the coolant fluid an increase from 0.9 ℃ to 14.4 ℃ was recorded. With increase of specific material removal rate from 0.15 to 0.65 mm 3/mm.s, F t/F n ratio was increased from (0.2 to 0.4), (0.6 to 1.67) for wet coolant and chilled air respectively. Despite of high F t/F n ratio and ground surface temperature, chilled air method has shown a surface waviness, W t from (2 to 5.6) μm. Microstructure examination of chilled air produced ground surface was comparable to those of using coolant fluids. Surface finish, R a of (0.45～0.7) μm was achieved for mold insert . This work will enable to have clear understanding about the quantitative influe nce of chilled air as well as the clamping method against the surface waviness o f thin mold insert.
基金Supported by Ningbo Key Technology R&D Program(2005B100058)
文摘Put forward a new kind of polishing method,ultrasonic magnetic abrasive fin-ishing(UMAF),and studied its mechanism of improving polishing efficiency.By analyzingall kind of forces acting on single abrasive particle in the polishing process and calculatingthe Size of the composition of forces,get the conclusion that UMAF will enhance the effi-ciency of the normal magnetic abrasive finishing(MAF)due to the ultrasonic vibration in-creases the cutting force and depth.At last the idea of designing the UMAF system basedon numerical control milling machine is put forward which is convenient to setup and willaccelerate the practical application of MAF.
文摘Through theoretical and experimental researeh about automatic polishing on thecurved surfaces of the moulds, the limitation of the polishing method at constant pressure, whichis adopted widely in the world, is analysed. Based on the analysis, a new polishing method atconstant pressure intensity is proposed, and the corresponding goveming equation and a com-prehensive polishing parameter are given as well.
