金刚石线锯成形加工硬脆材料圆弧的正交试验研究

针对硬脆材料圆盘件的成形切割问题,提出一种基于电镀金刚石线锯的成形切割方法并进行切割试验,采用3因素4水平正交试验系统研究切割线速度V(A)、转台W轴转速n(B)和金刚石线锯的张紧力F(C)对圆弧面径向跳动、线弓角度、切割效率以及表面粗糙度的影响规律。结果表明:W轴转速对圆弧的径向跳动(即圆度)、切割效率以及表面粗糙度影响最大,张紧力的影响次之,线速度的影响最小;张紧力对线弓角度影响最大,线速度的影响次之,W轴转速影响最小;在本试验条件范围内,经过试验验证得出的最优工艺参数组合为A3B1C1,即金刚石线锯的线速度为8.96 m/s,转台转速为0.25 r/h,张紧力为12 N。且径向跳动、线弓角度、切割效率和表面粗糙度的极差分析结果与其方差结果一致。

Orthogonal Experimental Study on Circular Arc Machining of Hard and Brittle Materials with Diamond Wire Saw

In order to solve the problem of shape cutting hard brittle material disc parts, a shape cutting method based on electroplated diamond wire saw was proposed and the cutting experiment was carried out. The effects of cutting speed V(A), rotating speed n(B) of rotary table W axis and tension force F(C) of diamond wire saw on radial runout, wire bow angle, cutting efficiency and surface roughness of circular arc surface were studied systematically by using three factor and four level orthogonal test. The results show that the influence of W-axis speed on the radial runout (roundness), cutting efficiency and surface roughness of arc is the largest, followed by the tension force and the linear velocity. The influence of tension force on the wire bow angle is the largest, followed by the linear velocity and the W-axis speed is the smallest. In the range of the test conditions, the optimal combination of process parameters are A3B1C1, that is, the linear speed of diamond wire saw is 8.96 m/s, the rotating speed of rotary table is 0.25 r/h, and the tension force is 12 N. The range analysis results of radial runout, wire bow angle, cutting efficiency and surface roughness are consistent with their variance results.