高温不锈钢的磨削温度测量与烧伤现象分析

针对高温不锈钢1Cr11Ni2W2MoV磨削过程中磨削区内部瞬时温度、磨削表面平均温度的测量方法以及工件表面平均温度与烧伤程度之间的关系进行了研究,分析了工件表面烧伤程度对材料金相组织的影响.通过研究得到了陶瓷结合剂CBN砂轮磨削1Cr11Ni2W2MoV时磨削区内部瞬时温度,证明工件表面的烧伤最直接因素是磨削表面的平均温度,在不同的磨削参数下,表面平均温度超过540℃就形成黄色的微烧伤,随着温度的升高,烧伤程度不断加重.同时,表面烧伤会使马氏体晶格变成细小的退火微晶变质层,烧伤越严重,微晶变质层的厚度越大.     

TA15钛合金薄板等离子弧对接焊缝疲劳特性研究

为了探索钛合金等离子弧焊接头的疲劳性能,本文依据TA15标准试件和轧制板材试件疲劳试验数据处理结果,采用当量应力集中系数法,在TA15薄板等离子弧焊和对接焊缝磨削组合工艺试件的疲劳试验基础上,确定了中值当量应力集中系数和安全当量应力集中系数,最后建立了该TA15薄板的S-N曲线,给出了应用结论。     

磨粒建模方法与切削过程仿真研究

针对砂轮表面上磨粒形状不规则、尺寸不确定的几何特征,研究了模拟实际磨粒的几何建模方法。采用随机空间平面切分正六面体的方法构建了具有实际磨粒几何特征的不规则多面体结构磨粒。基于LS-DYNA软件,采用流固耦合有限元法模拟了不规则多面体结构磨粒的切削过程。分析切削过程中工件材料的应力分布规律与切削变形规律,得出结论:工件材料的加工应力主要集中在与磨粒切削刃及棱角接触的区域;切屑沿磨粒挤压前面向上流动,并于挤压面法向方向上流出;磨粒挤压前角的增大有利于切屑的形成。利用陶瓷立方氮化硼(CBN)砂块进行了磨粒划擦试验,试验结果证实了磨粒切削仿真结果的准确性。     

环形热管砂轮强化磨削弧区换热研究

磨削过程中,在超过临界值的高磨削热流密度下,即使有再多的磨削液进入弧区也无济于事,因为磨削液既已处于成膜沸腾状态,由于工件表面所覆盖的汽膜层的阻挡,磨削液很难真正起到换热作用,如不及时采取相应的措施,工件必定很快发生烧伤。本文结合热工领域的换热技术,提出一种基于热管技术强化磨削弧区换热的全新构想,并在此基础上研制了新型的环型热管砂轮,以大幅提高弧区临界热流密度。最后,分别使用环形热管砂轮和普通砂轮进行磨削测温试验,验证了环形热管砂轮高速疏导磨削热,降低磨削温度,从而提高材料去除率的巨大潜力。     

Investigation on induction brazing of profiled cBN wheel for grinding of Ti-6Al-4V

Profiled monolayer cBN wheel was induction brazed for grinding of titanium dovetail slot in this study. Aimed at acquiring a uniform temperature distribution along the profiled surface and reducing the thermal deformation of the brazed wheel, a finite element model was established to investigate the temperature uniformity during induction brazing. A suitable induction coil and the related working parameters were designed and chosen based on the simulation results. Ag-Cu-Ti alloy and cBN grains were applied in the induction brazing experiment. The results showed geometric deformation of the brazed wheel was no more than 0.01 mm and chemical reaction layer were found on the brazed joint interface. Further validation tests were carried out by grinding of Ti-6Al-4V alloy. Compared to the electroplated wheel, the brazed wheel showed better performance such as low specific grinding energy and good ground quality in grinding of Ti-6Al-4V alloy. Abrasion wear was found to be the main failure mode for the induction brazed wheel, while adhesion and grains pull-out were the main failure mode for the electroplated wheel.     

Effect of creep feed grinding on surface integrity and fatigue life of Ni3Al based superalloy IC10

Ni₃Al-based superalloy IC10 is widely used in high temperature components of aero-engines because of its superior mechanical properties. In this paper, the creep feed grinding properties of IC10 were investigated experimentally. The effects of grinding parameters on the grinding forces and temperature were examined. Moreover, the influences of surface roughness and hardening on the high-cycle fatigue life of IC10 specimens were studied. To control the creep feed grinding parameters and enhance the fatigue life of IC10 components, the experimental results were summarized to offer a useful reference point. It is concluded that, the grinding depth is the most important factor which influencing the grinding forces and temperature; the surface roughness is the main and unfavorable factor on the fatigue life of IC10, while the surface hardening has a positive influence on the fatigue life; to obtain a better surface quality and improve the fatigue life of IC 10, the recommended grinding parameter domain involves wheel speed ∈ [15, 20] m/s, feed rate ∈ [150, 200] mm/min, and grinding depth ∈ [0.4, 0.5] mm.     

Interference and grinding characteristics in ultra-precision grinding of thin-walled complex structural component using a ball-end grinding wheel

As for ultra-precision grinding of difficult-to-process thin-walled complex components with ball-end grinding wheels, interference is easy to occur. According to screw theory and grinding kinematics, a mathematical model is established to investigate the interference and grinding characteristics of the ball-end wheel. The relationship between grinding wheel inclination angle, C axis rotation angle, grinding position angle and grinding wheel wear are analyzed. As the grinding wheel inclination angle increases, the C axis rotatable range decreases and the grinding position angle increases. The grinding position angle and wheel radius wear show a negative correlation with the C axis rotation angle. Therefore, a trajectory planning criteria for increasing grinding speed as much as possible under the premise of avoiding interference is proposed to design the grinding trajectory. Then grinding point distribution on the ball-end wheel is calculated, and the grinding characteristics, grinding speed and maximum undeformed chip thickness, are investigated. Finally, a complex structural component can be ground without interference, and surface roughness and profile accuracy are improved to 40.2 nm and 0.399 μm, compared with 556 nm and 3.427 μm before ultra-precision grinding. The mathematical model can provide theoretical guidance for the analysis of interference and grinding characteristics in complex components grinding to improve its grinding quality.     

精密研磨加工薄壁半盲孔及高精度平板的方法

本文着重从研磨加工的手法、研磨膏的配比、不同材料的研磨磨料选用等方面进行探讨,并详细叙述各种加工方式对产品质量的影响,通过典型零件加工技术的具体阐述,将研磨加工的方法及技巧做详细的描述,利于技术交流及推广.     

高效砂轮的在线检测

硬质氮化硼磨料在很多加工场合可经济地代替常用的金刚砂，碳化硅等磨料，在加工过程中可显著提高生产率。但如何高效获得周转和平面理想的磨削结果，本文叙述的测量砂轮径跳的方法可达到其目的。     

Al2O3陶瓷蠕动进给超声磨削特性试验研究

在改装成的超声磨削机床上进行了陶瓷超声磨削与普通磨削的对比试验,以揭示蠕动进给超声磨削加工的磨削特性及其材料去除机理。结果表明:当超声振动方向与磨削进给方向相同时,超声振动所引起的抛磨作用非常显著,超声磨削的表面粗糙度比机械磨削的低;Al2O3陶瓷在一般条件下超声磨削的去除方式仍属于脆性断裂,以晶粒粉碎、穿晶断裂为主,但伴随有沿晶断裂、弹性划擦、塑性流动等现象。