脆性光学材料的超声磨削实验研究

分别采用超声磨削和普通磨削加工方法加工了几种脆性光学材料,研究了几种主要工艺参数对工件加工表面粗糙度的影响。结果表明,超声频率和振幅、金刚石磨料粒度、切深、工具的横向进给速度和旋转速度等工艺参数对表面粗糙度的影响较大。通过比较发现,超声磨削方法比普通磨削方法具有更好的加工表面粗糙度,更高的材料去除率,以及更低的工具磨损量。     

平行磨削非轴对称非球面光学元件表面形貌

结合砂轮表面仿真及磨削过程的运动学仿真获得工件表面轮廓、形貌和粗糙度预计,可以作为磨削过程中的理论依据,是精密磨削加工技术中主要的研究内容之一。平行磨削技术是加工非轴对称非球面光学元件的重要手段,而相关的仿真过程报道还很少。提出一种基于平行磨削的精密磨削加工非球面表面生成的仿真方法,该方法主要包含使用高斯方法生成具有不同统计学特征的随机砂轮表面形貌,建立单磨粒运动轨迹方程和圆弧砂轮细分后与工件表面点接触的运动关系,据此给出平行磨削加工表面生成的数值算法,并对不同加工参数下的工件表面形貌进行仿真。仿真结果和测量结果的一致性验证了所给算法的正确性和有效性     

轴对称非球面磨削表面粗糙度和波纹度的分布特性

基于光栅平行磨削的加工方式,分析磨削参数对轴对称非球面表面粗糙度的影响,揭示轴对称非球面表面粗糙度的分布规律。研究砂轮与工件加工过程的干涉现象,阐述其对轴对称非球面表面波纹度的作用机理并提出影响其分布和大小的主要因素。结合磨削实验表明,垂直磨削方向的表面粗糙度明显比平行磨削方向上的大且数值呈现中部小、边缘大的分布特点。砂轮振动和插补步距分别是平行磨削和垂直磨削方向上表面波纹度产生的主要因素。     

轨迹成型法加工光学零件磨床中的微进给电控装置的研究

本文提出了一种在轨迹成型法加工光学零件磨床上实现脆性材料超精密磨削的微进给电控装置。试验表明,在轨迹成型法加工光学零件磨床上应用本装置对光学透镜进行磨削后,工件表面粗糙度可达Ｒａ＝０．０２μｍ,能够达到光学零件精磨的粗糙度要求。     

干冻磨削用低温冷风发生系统的设计

低温冷风发生系统是研究和应用低温冷风磨削的前提,低温冷风磨削是绿色磨削技术的重要分支之一。采用以单级蒸汽压缩制冷系统为核心,设计了一套干冻磨削用低温冷风发生系统,对该系统流程做了详细的描述及各个系统装置进行了详细的介绍。该低温冷风发生系统设计合理、结构简单、易于控制和操作。     

聚酰亚胺树脂粉在金刚石抛光片中的应用

本文介绍了聚酰亚胺树脂粉在金刚石抛光片中的应用。由于聚酰亚胺树脂耐热温度高和耐磨性好，由它制作的金刚石微粉抛光片具有使用寿命长、磨削效率高和被加工工件的表面粗糙度低等优点。ＴＧ－ＤＳＣ分析表明：聚酰亚胺树脂粉在３６０℃之前的热稳定性较好，固化温度选择在２３０℃。ＳＥＭ分析表明：在抛光过程中起磨削作用的主要是金刚石颗粒。如果树脂的耐磨性能差与耐热温度不高，金刚石颗粒过早地脱落是引起抛光片寿命不长与加工工件表面粗糙度高的主要原因。     

球面光学零件气囊抛光工艺参数优化的研究

针对球面光学零件,采用气囊抛光方法对其进行加工,以正交实验为实验方法,以球面光学零件材料去除率和表面粗糙度为目标,研究了5个主要影响因素(气囊压缩量、气囊转速、内部压力、抛光液浓度和工件曲率半径)对材料去除率和表面粗糙度的影响程度,并根据实验结果优选工艺参数,找出影响材料去除率和表面粗糙度的工艺参数优化组合。以去除率和表面粗糙度为目标工艺参数,在优选后的结果指导下,根据优选后的工艺参数,以控制表面粗糙度为目标,采用离散进动方式抛光球面光学零件,可获得超精密的光滑表面。     

大口径平面光学元件超精密加工技术的研究

为了解决激光核聚变装置中大口径平面光学元件的批量制造难题,将先进制造技术和传统抛光技术相结合,提出了一种新的工艺方法,即使用ELID(在线电解)磨削代替传统的铣磨和初抛工序,以提高生产效率。利用数控抛光将工件抛光至最终的面形精度,以提高生产效率和减少边缘效应。将连续抛光作为最终加工工序,使加工工件的表面粗糙度和波纹度达到工程要求。实验证明这一新的工艺方法是可行的。     

双图案非均匀耦合固结磨盘的设计及实验研究

针对传统固结磨盘因其表面沟槽形式单一而难以保证蓝宝石等硬脆性材料加工质量的问题,提出了一种螺旋-同心圆双图案非均匀耦合结构的新型固结磨盘(DPP)设计,并进行了实验研究。DPP采用螺旋槽作为排屑槽,降低了磨盘表面的堵塞程度,以保证加工表面获得低粗糙度,延长工具使用寿命;采用同心圆槽调整磨盘表面磨粒分布,提高了磨盘对工件材料的去除均匀性,以保证加工表面获得更高的平坦度。基于该设计原理,制备了用于蓝宝石加工的新型磨盘,并与传统网格槽型盘(GGP)进行对比。实验结果表明:采用DPP加工时工件表面的凹坑划痕数量更少,约为GGP的35%;研磨后磨盘表面堵塞程度更低,约为GGP的30%。虽然,采用DPP加工时工件材料去除率较GGP低14%,但是材料去除厚度非均匀性为0.0494,比GGP低32%,表面粗糙度为129.4μm,比GGP低16.2%。因此,采用DPP加工时工件材料去除分布更均匀,工件表面质量更好。实验结果证明:DPP不仅可以获得更好的工件表面质量,还可以延长磨盘的使用寿命,可满足对高质量表面、大规模生产蓝宝石等脆硬材料的精密研磨加工需求。     

基于自相关函数的非平面表面粗糙度的图像纹理研究

采用自相关函数对不同加工工艺形成的非平面工件表面粗糙度进行了研究。讨论了自相关函数及其扩展度参数与图像纹理特性的关系,构建了实验装置,利用图像处理软件对实验所得的激光散斑图像进行了处理,得到了自相关函数及其扩展测度参数随表面粗糙度的变化曲线。为研究非平面工件的粗糙度,提供了一种新的方法。     

Correlation between full width at half maximum (FWHM) of XRD peak with residual stress on ground surfaces

The full width at half maximum (FWHM) of XRD profiles is used to characterize different material properties and surface integrity features. However, there is no literature available that discusses the nature of the correlation between the FWHM of XRD peaks with induced surface residual stress upon grinding with simultaneous occurrence of plastic deformation, formation of white layer, grain elongation, change in microhardness, etc. AISI 1060 steel samples were ground under different grinding domains, i.e. conventional abusive grinding, conventional grinding, cBN grinding and high speed grinding with moderately deep cut. Induction of tensile and compressive residual stress, microstructural changes, white layer formation, grain refinement, plastic deformation, grain elongation and change in microhardness were observed upon grinding AISI 1060 steel. A correlation was established between the FWHM of XRD peaks and surface residual stress when simultaneous changes in microhardness and microstructure, grain elongation, plastic deformation and formation of white layer take place due to grinding. The correlation between FWHM of XRD peak and residual stress appears to be nonlinear due to simultaneous change in other aspects of surface integrity.     

侧吹气体对光纤激光修锐青铜金刚石砂轮等离子体特性影响

为了研究辅助侧吹氩气对光纤激光修锐青铜结合剂金刚石砂轮等离子体的影响,利用高速摄像机拍摄不同侧吹工艺参数下等离子体空间膨胀形态,结果表明：氩气降低了等离子体的膨胀高度,随着压力增加,等离子体的膨胀距离减小,等离子抑制作用增强。 利用光谱仪研究了等离子体发射光谱在砂轮径向上的最大值随氩气压力的变化情况,并根据Boltzmann斜线法和Stark展宽法,计算不同氩气压力下等离子体在砂轮径向上电子温度和电子数密度的最大值,结果表明：气体压力增大,等离子体光谱线强度先增大后减小,等离子体光谱线强度在0.2 MPa时达到峰值,较大的氩气压力明显降低等离子体电子温度和电子数密度,从而减小对砂轮表面形貌的影响。 利用超景深三维扫描仪观测添加侧吹气体前后砂轮表面形貌,结果表明：0.5 MPa侧吹氩气后,砂轮表面形貌质量明显优于未添加侧吹气体时。     

变截面主流加速对超音速气膜冷却的影响

本文对扩张通道和直通道中的超音速气膜冷却进行了数值模拟,分析了主流加速和不加速两种情况下超音速气膜冷却的差异.计算结果表明,在主流加速的情况下,超音速气膜冷却的效果要好于相同进口条件下主流不加速的情况,并且这种差异越到下游越明显.同时,在本文计算的工况范围中,无论主流加速还是不加速,增大主流进口马赫数或者减少冷却流进口马赫数都使气膜冷却效率下降,而壁面静压则由主流气体决定.     

Novel processing of Barkhausen noise signal for assessment of residual stress in surface ground components exhibiting poor magnetic response

The Barkhausen Noise Analysis (BNA) technique has been utilised to assess surface integrity of steels. But the BNA technique is not very successful in evaluating surface integrity of ground steels that exhibit poor micro-magnetic response. A new approach has been proposed for the processing of BN signal and two newly proposed parameters, namely ‘count’ and ‘event’, have been shown to correlate linearly with the residual stress upon grinding, with judicious choice of user defined ‘threshold’, even when the micro-magnetic response of the work material is poor. In the present study, residual stress induced upon conventional plunge surface grinding of hardened bearing steel has been investigated along with unhardened bearing steel for benchmarking. Moreover, similar correlation has been established, when primarily compressive stress is induced upon high speed grinding using cBN wheel with moderately deep cut suppressing the micro-magnetic response from the ground medium carbon steel as the work material.     

冷藏展示柜冷却风道的设计及数值模拟

以冷藏展示柜强制冷却冷凝器的冷却风道为对象,建立了物理数学模型,用SIMPLE方法计算了3种型式冷凝器冷却风道空气流场,通过速度分布图和速度矢量图分析了各型式风道冷凝器和压缩机冷却效果,结合冷藏展示柜的结构和实际应用提出了冷却风道优化的方向,为冷藏展示柜的优化设计提供了参考.     

功率超声珩磨磨削区空化声场的建模与仿真研究

通过建立Φ47功率超声珩磨磨削区流体-结构耦合声场的理论模型,采用ANSYS有限元分析软件对磨削区的空化声场进行了仿真分析,得出磨削区二维、三维空化声场的分布情况和声压幅值,并利用超声波功率测量仪对磨削区的空化声场进行模拟实验测量。结果表明:在谐振频率18.6 kHz下,声场主要集中在油石的中部,二维和三维声场的声压最大值分别为1.39 MPa和1.47 MPa,与实验测得声压最大值1.3 MPa在同一个数量级,为进一步研究功率超声珩磨空化效应提供理论和实验的基础。      

Acoustic emission monitoring of high speed grinding of silicon nitride

Acoustic emission (AE) monitoring of a machining process offers real-time sensory input which could provide tool condition and part quality information that is critical to effective process control. However, the choice of sensor, its placement, and how to process the data and extract useful information are challenging application-specific questions which researchers must consider. Here we report an effort to resolve these questions for the case of high speed grinding of silicon nitride using an electroplated single-layered diamond wheel. A grinding experiment was conducted at a wheel speed of 149 m s-1 and continued until the end of the useful wheel life. AE signal data were then collected for each complete pass at given grinding times throughout the useful wheel life. We found that the amplitude of the AE signal monotonically increases with wheel wear, as do grinding forces and energy. Furthermore, the signal power contained in the AE signal proportionally increases with the associated grinding power, which suggests that the AE signal could provide quantitative information of wheel wear in high-speed grinding, and could also be used to determine when the grinding wheel needs replacement.     

Investigating the effect of different asphaltene structures on surface topography and wettability alteration

This paper aims at investigation of the effect of asphaltene structure on wettability and topography alteration of a glass surface as a result of asphaltene precipitation. In order to provide a better insight into the topography alteration, a bi-fractal approach was employed. Such an approach is capable of discriminating topography alteration in two different surface types, namely, macro-asperities and micro-asperities. The observed variation of the fractal dimension in the two surface types could be considered as the consequence of different asphaltene sources. Therefore, the structure of different asphaltene sources was carefully examined. The effect of asphaltene structure is more pronounced for asphaltene precipitation at higher pressure. It was revealed that asphaltene particles of high complexity and with larger poly-aromatic rings tend to be detached easier at higher pressure than those with smaller poly-aromatic rings. Another evidence to emphasize the significance of asphaltene structure was given through wettability alteration. It was found that asphaltene particles with larger poly-aromatic rings turn the surface less oil wet at higher pressure. It seems that the difference in wetting condition and surface topography alteration of different asphaltene sources roots in their different structures.     

Experimental verification of nanoparticle jet minimum quantity lubrication effectiveness in grinding

In our experiment, K-P36 precision numerical control surface grinder was used for dry grinding, minimum quantity lubrication (MQL) grinding, nanoparticle jet MQL grinding, and traditional flood grinding of hardened 45 steel. A three-dimensional dynamometer was used to measure grinding force in the experiment. In this research, experiments were conducted to measure and calculate specific tangential grinding force, frictional coefficient, and specific grinding energy, thus verifying the lubrication performance of nanoparticles in surface grinding. Findings present that compared with dry grinding, the specific tangential grinding force of MQL grinding, nanoparticle jet MQL grinding, and flood grinding decreased by 45.88, 62.34, and 69.33 %, respectively. Their frictional coefficient was reduced by 11.22, 29.21, and 32.18 %, and the specific grinding energy declined by 45.89, 62.34, and 69.45 %, respectively. Nanoparticle jet MQL presented ideal lubrication effectiveness, which was attributed to the friction oil film with strong antifriction and anti-wear features formed by nanoparticles on the grinding wheel/workpiece interface. Moreover, lubricating properties of nanoparticles of the same size (50 nm) but different types were verified through experimentation. In our experiment, ZrO₂ nanoparticles, polycrystal diamond (PCD) nanoparticles, and MoS₂ nanoparticles were used in the comparison of nanoparticle jet MQL grinding. The experimental results manifest that MoS₂ nanoparticles exhibited the optimal lubricating effectiveness, followed by PCD nanoparticles. Our research also integrated the properties of different nanoparticles to analyze the lubrication mechanisms of different nanoparticles. The experiment further verified the impact of nanoparticle concentration on the effectiveness of nanoparticle jet MQL in grinding. The experimental results demonstrate that when the nanoparticle mass fraction was 6 %, the minimum specific tangential grinding force, frictional coefficient, and specific grinding energy were 1.285 N/mm, 0.382, and 57.825 J/mm³, respectively. When nanoparticle mass fraction was smaller than 6 %, lubrication effects of nanoparticle jet MQL increased with the rising nanoparticle mass fraction. When nanoparticle mass fraction was larger than 6 %, lubrication effects of nanoparticle jet MQL decreased with the rising nanoparticle mass fraction.