精密磨削中修整金刚石磨轮的新技术——双电极接触放电修整

本文介绍了一项修整金属结合剂金刚石磨轮的新技术——双电极接触放电修整。论述了修整原理、工艺、效率、质量评价以及应用实例。     

基于混合推理的超硬磨料砂轮电火花修整数据库系统研究

根据金属结合剂CBN成型砂轮电火花修整实验结果和电火花修整用电规则,详细讨论了电火花放电参数对修整效果的影响。在此基础上提出基于实例和规则推理的方法优化放电参数,并对粗、精修整优化的放电参数进行了实验验证,实验结果表明优化后的放电参数具有较好的修整效果。利用SQL Sever 2005和Visual Basic6.0开发了电火花修整超硬磨料砂轮数据库系统,通过该数据库系统可快速查询电火花修整金属结合剂CBN成型砂轮实例,并能实现对实例进行放电参数优化的功能。     

金属结合剂金刚石砂轮电火花修整中电规准的选择

电火花修整是金属结合剂金刚石砂轮的高效修整方法．从电火花放电规准对整形效率、整形精度及修锐质量的试验研究，得出：对于不同的金刚石磨粒尺寸及在不同的修整阶段应选用不同的电火花规准．尤其在电火花修锐阶段，一定要使电火花放电规准同磨粒尺寸相匹配．     

一种快速磨削新技术

美国UnitedGrindingTechnologiesInc.公司准备在其BlohmPlanomat蠕缓磨床中采用一种新的CNC磨轮修整技术．该技术无需使用修整工具就可生成磨轮轮廓．提高磨轮修整和磨床的调整速度．这种新技术采用一组通用金刚石成形修整磨盘对摩轮进行仿形轮廓加工．将其同为BlohmPlanomat而新近开发的Profile软件结合使用，用户可进行复杂的磨轮轮廓修整并生成磨削程序．Profile软件根据所需磨轮轮廓的CAD文件生成CNC修整轨迹．并将其下载到磨床的控制软件中．利用Profile软件还可对机床的工作过程及机床所有轴向上的运动进行离线模拟．BlohmPl…     

用金刚石滚轮修整磨轮及其对磨轮的磨削性能的影响

引言 在磨削过程中对磨轮进行修整的目的有二:一是恢复磨轮的切削性能;二是使磨轮重新获得准确的型面。通常采用的修整工具有钢质滚轮修整器和金刚石修整器两大类。金刚石修整器又可分为直线移动式和旋转式两种,本文只论述后一种。     

金属结合剂砂轮的研究与发展

介绍了近年来有关金属结合剂砂轮的国内外研究进展,重点是金属结合剂砂轮的修整技术,也对金属结合剂砂轮的发展提出了看法。     

金属结合剂金刚石微粉砂轮电火花修整用脉冲电源的研制

根据金属结合剂金刚石微粉砂轮电火花修整对脉冲电源的要求，研制出一种新型的电火花修整用脉冲电源，并介绍了该电源的设计、工作原理和特点。     

ELID超精密镜面磨削钝化膜状态变化的研究

建立了ELID磨削系统的电解反应回路等效模型,提出用极间电流表征金属结合剂砂轮表面的钝化膜状态,分析了钝化膜在ELID超精密镜面磨削电解预修锐阶段、在线电解修整动态磨削阶段和光磨阶段的状态变化。     

电解在线修整在超精密磨削中的应用

介绍了由铁系结合剂砂轮、直流脉冲电源和水溶性磨削液等构成的电解在线修整磨削方法的原理、特性及镜面磨削的应用方式．     

难加工金属材料放电诱导可控烧蚀高效加工技术

介绍了一种放电诱导烧蚀加工方法,即向加工区域可控地通入氧气,在电火花放电诱导作用下首先对加工材料进行活化,而后伴随着氧气的通入产生金属燃烧反应,利用金属燃烧释放的巨大化学能蚀除材料,从而大大提高材料去除率,并通过控制氧气及采用电火花修整以保障加工表面的质量.该加工方法与被加工材料的力学性能无关,仍然属于无宏观切削力方式,其克服了难加工材料机械加工困难及电火花加工效率受制于脉冲电源的难题,适合于“车、铣、钻、成形、打孔”等各种加工形式.该加工方法改变了难加工材料能进行加工的准则,实现了“能烧即能加工”.对淬火Cr12进行放电诱导烧蚀铣削加工,效率比传统电火花加工高10倍以上且表面质量相当;进行放电诱导雾化烧蚀深盲型孔加工,蚀除效率为电火花的5.45倍,最大加工深度达到132mm且还能继续加工.     

ELID磨削硬脆材料精密和超精密加工的新技术

金属基超硬磨料砂轮在线电解修整（ＥｌｅｃｔｒｏｌｙｔｉｃＩｎｐｒｏｃｅｓＤｒｅｓｉｎｇ,简称ＥＬＩＤ）磨削技术是国外近年发展起来的一种硬脆材料精密和超精密加工新技术。本文介绍了ＥＬＩＤ磨削技术的基本原理、工艺特点和国内外研究应用情况。应用ＥＬＩＤ磨削技术,可对工程陶瓷等硬脆材料实现高效率磨削和精密镜面磨削     

Review on monolayer CBN superabrasive wheels for grinding metallic materials

A state-of-the-art review on monolayer electroplated and brazed cubic boron nitride (CBN) superabrasive wheels for grinding metallic materials has been provided in this article. The fabrication techniques and mechanisms of the monolayer CBN wheels are discussed. Grain distri-bution, wheel dressing, wear behavior, and wheel performance are analyzed in detail. Sample appli-cations of monolayer CBN wheel for grinding steels, titanium alloys, and nickel-based superalloys are also provided. Finally, this article highlights opportunities for further investigation of mono-layer CBN grinding wheels.     

铸铁结合剂金刚石砂轮电火花整形影响因素初探

简单介绍了铸铁结合剂金刚石砂轮电火花整形的原理,对电火花整形的影响因素进行了分析,为以后金属结合剂金刚石砂轮的电火花整形实验提供了一些经验。     

钛合金TC4电火花诱导可控烧蚀高效磨削技术研究

利用大部分金属尤其是难加工金属的可燃特性,开发一种针对难加工金属材料的新加工工艺——电火花(EDM)诱导可控烧蚀高效磨削技术。采用开槽导电砂轮进行磨削加工,首先利用导电区域与加工材料产生电火花诱导放电并通入助燃氧气,使材料表面产生电火花引燃烧蚀并软化,然后将已烧蚀和软化的材料磨除,对钛合金TC4进行烧蚀磨削试验,并与常规电火花磨削和机械磨削进行对比,分析了材料去除率(RMM)、表面质量和机床主轴电机功率变化等指标。结果表明,在试验条件下,烧蚀磨削在放电利用率提高的同时可获得表面粗糙度为0.59 μm的加工表面,与机械磨削的表面粗糙度值相近,而相同条件下电火花磨削的表面粗糙度为1.29 μm。由于烧蚀后产生了软化层,在切深小于软化层厚度的条件下,相对于电火花磨削和机械磨削状况,烧蚀磨削主轴电机功率相比空载时的增加值分别降低了95.2%和96.8%。此工艺方法可大大提高难加工材料的可磨削性能。     

TC4钛合金高效磨削加工用环形热管砂轮的研制

针对航空航天高强韧性难加工材料TC4钛合金在磨削加工中存在磨削温度高而导致工件表面烧伤的问题,提出利用热管换热技术冷却磨削弧区的新方法.分析了环形热管砂轮在加工中对磨削弧区的强化换热原理,并设计制作出能够用于磨削加工的环形热管砂轮,同时实现了对砂轮基体内环形管腔的密封、抽真空、精确注液与机械式真空封口.最后,在相同磨削工艺条件下,使用环形热管砂轮和无热管砂轮进行TC4钛合金缓进给深切磨削对比试验,验证了环形热管砂轮对磨削弧区温度的控制效果.试验结果表明:设计制作的环形热管砂轮在TC4钛合金高效磨削过程中可以有效降低磨削温度,避免工件表面出现烧伤.     

Grain erosion wear properties and grinding performance of porous aggregated cubic boron nitride abrasive wheels

Cubic boron nitride (cBN) superabrasive grinding wheels exhibit unique advantages in the grinding of difficult-to-cut materials with high strength and toughness, such as titanium alloys and superalloys. However, grinding with multilayered metallic cBN superabrasive wheels faces problems in terms of grain wear resistance, the chip storage capability of the working layers and the stability and controllability of the dressing process. Therefore, in this work, novel metallic cBN superabrasive wheels with aggregated cBN (AcBN) grains and open pore structures were fabricated to improve machining efficiency and surface quality. Prior to the grinding trials, the air-borne abrasive blasting process was conducted and the abrasive blasting parameters were optimized in view of wear properties of cBN grains and metallic matrix materials. Subsequently, the comparative experiments were performed and then the variations in grinding force and force ratio, grinding temperature, tool wear morphology and ground surface quality of the multilayered AcBN grinding wheels were investigated during machining Ti–6Al–4V alloys. In consideration of the variations of grain erosion wear volume and material removal rate per unit of pure metallic matrix materials as the abrasive blasting parameters changes, the optimal abrasive blasting parameters were identified as the SiC abrasive mesh size of 60# and the abrasive blasting distance and time of 60 mm and 15 s, respectively. The as-developed AcBN grains exhibited better fracture toughness and impact resistance than monocrystalline cBN (McBN) grains because of the existence of metal-bonded materials amongst multiple cBN particles that decreased crack propagation inside whole grains. The metallic porous AcBN wheels had lower grinding forces and temperature and better ground surface quality than vitrified McBN wheels due to the constant layer-by-layer exposure of cBN particles in the working layer of AcBN wheels.     

Modeling and experiment of grinding wheel axial profiles based on gear hobs

Hobbing is one of the crucial gear manufacturing processes with high precision and high efficiency. In order to improve the accuracy of hobbing and hob relief grinding, more precise grinding wheels are demanded for relief grinding in the production of gear hobs. In this paper, a new and accurate mathematical method for calculating the axial profile of grinding wheel based on the corresponding gear hob to be ground is proposed. Considering that most researches have been conducted to focus on the optimization of hob geometric feature and only can be applied to a specific type of hand of helix and rake angle of gear hobs. The method in this paper can be served as a general algorithm for generating axial profile of grinding wheels on the basis of the spatial envelope theory, the principle of coordinate system transformation, and studies on normal profile of single-tooth. The accuracy of grinding hobs is based on applying the approach in practical manufacturing. Taking two typical different kinds of pre-grinding gear hobs as examples for calculation and experiment, the results of tooth profile errors strengthen the position that the validity and feasibility of this method, it can be employed for gear hob design and grinding processing.     

硅微晶玻璃超精密磨削技术的研究

介绍了应用铸铁结合剂金刚石微粉砂轮和在线电解修整（ＥｌｅｃｔｒｏｌｙｔｉｃＩｎ－ｐｒｏｃｅｓＤｒｅｓｉｎｇ,简称ＥＬＩＤ）磨削技术对硅微晶玻璃材料零件进行的超精密磨削实验。通过改变磨削参数并用力和声发射信号对磨削过程进行在线检测,对硅微晶玻璃材料的磨削进行了分析研究。实验结果表明用ＥＬＩＤ磨削方法磨削硅微晶玻璃可以达到良好的镜面磨削效果     

断续 CBN 砂轮缓进给磨削 K417 航空叶片材料的研究

 全面比较了用Al2O3和CBN磨削K417铸造高温合金时的磨削效果，指出：Al2O3不适于高效磨削K417之类的航空难加工材料，而CBN是实现该材料高效深切磨削的有效工具。通过大量实验，验证了断续CBN砂轮缓进给磨削K417时的技术优势，解决了树脂结合剂应用于断续磨削时所遇到的新问题。分析显示出该技术具有很好的应用前景和极大的推广价值。     

超精密磨削中的超硬砂轮修整技术

论述了超精密磨削中广泛应用的几种超硬砂轮修整技术,分析了它们的工作原理,特点和适用范围.