CN102729101A - Solid particle grinding fluid combined machining process and device - Google Patents
Solid particle grinding fluid combined machining process and device Download PDFInfo
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- CN102729101A CN102729101A CN2012102085842A CN201210208584A CN102729101A CN 102729101 A CN102729101 A CN 102729101A CN 2012102085842 A CN2012102085842 A CN 2012102085842A CN 201210208584 A CN201210208584 A CN 201210208584A CN 102729101 A CN102729101 A CN 102729101A
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Abstract
The invention relates to a solid particle grinding fluid combined machining process and a solid particle grinding fluid combined machining device. The device comprises an oil tank, wherein the oil tank is connected with an ultrasonic vibration generator through an electromagnet; a coarse particle size region, a middle particle size region and a fine particle size region are formed inside the oil tank; each region is provided with a corresponding oil supply opening and connected with a corresponding hydraulic pipeline; the hydraulic pipelines are connected with an electromagnetic directional valve; an outlet of the electromagnetic directional valve is connected with a slurry pump and an overflow valve through the hydraulic pipelines; the overflow valve is connected with an ultrasonic vibration spray nozzle through a metal hose; and both the ultrasonic vibration generator and the electromagnet are connected with a controller. By the process and the device, workpieces are ground, lapped and polished and subjected to combined machining by an in-process dressing grinding wheel continuously; the advantages that solid particles are high in cooling performance and impact machining performance are fully utilized; grinding burn is effectively avoided; the surface integrity and machining accuracy of the workpieces are improved; a high-efficiency, low-consumption, environment-friendly and resource-saving low-carbon clean production process is realized; and the process and the device have an important significance.
Description
Technical field
The present invention relates to combined machining method and device in a kind of field of machining, relate in particular to a kind of solid particle grinding fluid complex machining process and device.
Background technology
In plain grinding,, increase surface roughness and percent ripple because high temperature and the excessive plastic deformation of workpiece surface material, micro-crack, residual stress and the superficial layer pollution etc. that roll generation can form the blemish layer on workpiece.This will influence part fatigue strength, etch resistant properties and contact stiffness, make part satisfy not higher instructions for use.Therefore, strength member need be removed the polishing processing of blemish layer, reduction roughness and percent ripple after grinding.
Can know that by the enhanced heat exchange theory heat-transfer capability of solid is much larger than liquids and gases.The thermal conductivity factor of solid material is than fluent material big tens times even hundreds of times under the normal temperature.The thermal conductivity factor of liquid that is suspended with metal, nonmetal or polymer solid particles is big more many than neat liquid.In the grinding medium, add solid particle, aluminium oxide, carborundum, silicon nitride, diamond, the cubic boron nitride abrasive materials that generally adopts in processing like polishing can further increase the thermal conductivity factor of grinding medium, improves the ability of convective heat transfer.
For this reason; The applicant in first to file No. 201010004222.2 nanometer grinding process and nanometer grinding liquid patent; It adds solid particle processes the solid particle grinding fluid in the grinding medium, promptly solid particle mixes with certain volume mark content proportioning with grinding fluid (mineral oil or emulsion).
But at present; Grinding need be carried out on different equipment with this two procedures of polishing processing, and this has not only increased man-hour and cost, and workpiece is in transmission course; Unnecessary knocking against hard, scratch takes place in its surface easily, has influence on the crudy and the accuracy of form and position on surface.The major reason that the grinding of workpiece and polishing processing can not be carried out on same equipment continuously is: the used medium of two operations is different; Need inject the grinding fluid of cooling, lubricated and cleaning action during grinding; Polishing processing then need be injected the polishing liquid that abrasive material mixes with fluid, and the device that does not still have to realize grinding and the incorporate process equipment of polishing at present and in an equipment, can supply these the two kinds used liquid mediums of processing simultaneously.If assembling two cover liquid feed devices on same grinding machine, both inconvenience was installed, and also was awkward, and also can increase equipment cost and operating cost.
Summary of the invention
The object of the invention is exactly can not be arranged on the problem on the same equipment for solving present grinding and polishing processing; A kind of solid particle grinding fluid complex machining process and device are provided; It is filtered into three zones with the solid particle grinding fluid of splendid attire in the fuel tank; Be respectively zone, coarse grain footpath, middle particle size region and fine grain zone; The abrasive size that the fine grain zone is contained is 5 ~ 10 μ m, and the abrasive size that middle particle size region contains concentrates on 11 ~ 50 μ m, and the abrasive size that zone, coarse grain footpath is contained concentrates on 51 ~ 63 μ m.The solid particle grinding fluid in fine grain zone is used in grinding, further improves the exchange capability of heat of grinding medium; The solid particle grinding fluid of particle size region during polishing processing is used carries out polishing processing to the workpiece after the grinding, further improves the surface quality and the surface integrity of workpiece; If emery wheel rust in addition; The forfeiture grinding capacity; Can use the solid particle grinding fluid in zone, coarse grain footpath; With very big speed and acceleration impinging sand wheel surface, remove the bond between the emery wheel abrasive material by means of the abrasive material that suspends in the ultrasonic vibration nozzle solid particles grinding fluid, carry out online dressing emery wheel.It can carry out the compound processing course of grinding, polishing processing, online dressing emery wheel continuously on a device; Make full use of solid particle and had stronger cooling performance and the advantage of impacting working ability; Effectively solve grinding burn; Improve surface of the work integrality and machining accuracy, realize efficient, low consumption, environmental friendliness, the green cleaner production of resource-effective low-carbon (LC), have very important meaning.
For realizing above-mentioned purpose, the present invention adopts following technical scheme:
A kind of solid particle grinding fluid complex machining device, it comprises fuel tank, fuel tank is connected with the ultrasonic vibration generator through electromagnet; Fuel tank internal is provided with zone, coarse grain footpath, middle particle size region and fine grain zone, and each zone is provided with the oil-feed port of a correspondence and is connected with corresponding fluid pressure line; Fluid pressure line is connected with solenoid directional control valve, and the logical fluid pressure line of electromagnetic switch valve outlet port is connected with slush pump, overflow valve, and overflow valve is connected with the ultrasonic vibration nozzle through metal hose; Ultrasonic vibration acoustical generator, electromagnet all are connected with controller.
Said fuel tank side is provided with liquid level gauge, is provided with bleeder plug in the bottom, and the top is provided with scavenging air valve; Simultaneously in fuel tank, also be provided with the oil back region, the oil back region is provided with oil return opening, and the semi-surrounding zone is formed by the dividing plate of interlaced arrangement in the oil back region; Outside this semi-surrounding zone fine grain zone, middle particle size region and zone, coarse grain footpath; Wherein, The fine grain zone is that particle diameter is that the sieve plate of 5-10um surrounds by the aperture; In particle size region be that the sieve plate of 11-50um surrounds by particle diameter, zone, coarse grain footpath be that fine grain is regional, middle particle size region remaining area outward, its abrasive size is at 51-63um.
Said solenoid directional control valve is a three-position four-way valve, and it comprises valve body and spool, on valve body, is provided with A, B, three inlets of C, is connected with the fine grain zone with zone, coarse grain footpath, middle particle size region respectively; Also being provided with a P outlet is connected with pipeline; Spool is installed in the passage of valve body, through open or close A, B, C, each mouthful of P along moving of passage.
Said ultrasonic vibration nozzle comprises upper endpiece and lower endpiece, is provided with piezoelectric ceramics between the two, and by hold-down bolt the three is compressed; Lower endpiece is connected through bolt and horn, and the horn lower end is a taper seat, and being provided with cross section in it is the spray orifice II of rectangle, and along short transverse, width does not become 2 ~ 5mm, and length becomes big gradually; Laterally advance hole I for perpendicular setting above spray orifice II; Piezoelectric ceramics is connected with the nickel sheet, and the nickel sheet is connected with supersonic generator, and supersonic generator is connected with controller.
Also be provided with Pressure gauge, flowmeter between said overflow valve and the metal hose.
Said horn is the ceramic material horn.
The length of said horn is the integral multiple of sound wave half-wavelength, and piezoelectric ceramics adds that the length of lower endpiece is the integral multiple of sound wave half-wavelength; Horn top cylindrical cross-section is long-pending to be equated with the cross-sectional area of lower endpiece, and control horn lower cone cross-sectional area makes circular cone lower surface amplitude amplify 1.2 ~ 2.6 times.
A kind of processing technology that adopts solid particle grinding fluid complex machining device, carry out in plain grinding, polishing and the plain grinding process following to workpiece to the operating process of emery wheel dressing:
Workpiece is carried out plain grinding:
(1) electromagnet energising makes it hold fuel tank;
(2) ultrasonic vibration generator energising mixes grinding fluid and abrasive material in the fuel tank;
(3) adjust the ultrasonic vibration nozzle angle;
(4) oil pressure relief of adjusting overflow valve makes it be set to 0.4 ~ 0.5MPa;
(5) solenoid directional control valve electric, spool moves, making fuel tank fine grain zone is that abrasive size is that the solid particle grinding fluid of 5 ~ 10 μ m is connected with slush pump through pipeline;
(6) workpiece location, clamp, start emery wheel and slush pump, the solid particle grinding fluid through solenoid directional control valve, slush pump, flowmeter, metal hose, ultrasonic vibration nozzle get into emery wheel between the workpiece, promptly carry out plain grinding; In the plain grinding process, as workpiece surface roughness R
aWhen being 3.2 ~ 1.6 μ m, promptly finish plain grinding, begin workpiece is carried out polishing; In the plain grinding process, if the emery wheel blunt, the surface quality of workpiece and precision all can descend, and need carry out online dressing this moment to emery wheel, remove the bond between abrasive material, change step (9) this moment over to;
Workpiece is carried out polishing:
(7) solenoid directional control valve dead electricity, spool is got back to the centre position, and making particle size region in the fuel tank is that abrasive size is that the solid particle grinding fluid of 11 ~ 50 μ m is connected with slush pump through pipeline;
(8) emery wheel stops to cut feeding, regulates other grinding parameters, and the solid particle grinding fluid of particle diameter abrasive material gets into grinding area in containing under the emery wheel drag interaction, begins workpiece is carried out polishing;
(9) during dressing, stop emery wheel earlier, close slush pump;
(10) the adjustment nozzle location make nozzle perpendicular to the emery wheel outer round surface, and to make the distance of nozzle and emery wheel outer round surface is 5 ~ 10mm;
(11) solenoid directional control valve 5 electric, spool moves, making zone, fuel tank coarse grain footpath is that abrasive size is that the solid particle grinding fluid of 51 ~ 63 μ m is connected with slush pump through pipeline;
(12) start emery wheel, grinding wheel speed is too not high, and speed is 20 ~ 60r/min;
(13) open slush pump, make the solid particle grinding fluid entering solenoid directional control valve, slush pump, flowmeter, metal hose, the ultrasonic vibration nozzle that contain coarse grain footpath abrasive material vertically spray to the emery wheel cylindrical;
(14) supersonic generator energising makes the ultrasonic vibration nozzle begin vibration, for solid particle grinding fluid dressing emery wheel provides energy;
When (15) dressing finishes, close slush pump, supersonic generator, solenoid directional control valve, ultrasonic vibration acoustical generator, electromagnet successively.
The invention has the beneficial effects as follows: the compound processing course that on a device, can carry out grinding, polishing processing, online dressing emery wheel continuously.Be filtered into three zones after the solid particle grinding fluid of splendid attire in the fuel tank mixed through ultrasonic vibration; Be respectively zone, coarse grain footpath, middle particle size region and fine grain zone; The abrasive size that the fine grain zone is contained is 5 ~ 10 μ m; The abrasive size that middle particle size region contains is 11 ~ 50 μ m, and the abrasive size that zone, coarse grain footpath is contained is 51 ~ 63 μ m.Through changing the different operating position of solenoid directional control valve, the solid particle grinding fluid of trizonal different abrasive sizes in the fuel tank is connected with slush pump through pipeline, realize that respectively grinding, polishing are processed, the compound processing course of online dressing emery wheel.In order to improve the dressing ability and the effect of solid particle grinding fluid; The solid particle grinding fluid in zone, coarse grain footpath is not only under the liquid supply pressure effect of slush pump; In addition also by means of the abrasive material that suspends in the ultrasonic vibration nozzle solid particles grinding fluid with very big speed and acceleration impinging sand wheel surface, further improve the ability of dressing emery wheel.
The solid particle grinding fluid in fine grain zone is used in grinding, further improves the exchange capability of heat of grinding medium; The solid particle grinding fluid of particle size region during polishing processing is used carries out polishing processing to the workpiece after the grinding, further improves the surface quality and the surface integrity of workpiece; If emery wheel rust in addition; The forfeiture grinding capacity can use the solid particle grinding fluid in zone, coarse grain footpath, by means of the additional-energy impinging sand wheel surface of suspension grinding material in the ultrasonic vibration nozzle solid particles grinding fluid; Remove the bond between the emery wheel abrasive material, carry out online dressing emery wheel.The present invention has not only made full use of the powerful exchange capability of heat of solid particle; Avoided being easy to generate grinding burn in traditional grinding, the difficult problem that surface integrity worsens, but also grinding, polishing processing and online dressing emery wheel are accomplished on the same station on same the equipment; Integrated degree is high; Machining accuracy is high and surface quality is good, has great importance for promoting conventional equipment with advanced technology, and is great to the national economy influence.
Description of drawings
Fig. 1 solid particle grinding fluid complex machining device hydraulic scheme;
Fig. 2 fuel tank positive two is surveyed view;
Fig. 3 fuel tank top plan view;
Fig. 4 fuel tank section rotation diagram;
Fig. 5 solenoid directional control valve structure chart;
Fig. 6 solenoid directional control valve fundamental diagram;
Fig. 7 ultrasonic vibration nozzle arrangements cutaway view;
Fig. 8 departs from the displacement schematic diagram calculation.
Table 1 solenoid directional control valve sequence of movement table.
Wherein, 1-fuel tank, 2-electromagnet, 3-ultrasonic vibration generator, 4-fluid pressure line, 5-solenoid directional control valve; The 6-slush pump, 7-overflow valve, 8-Pressure gauge, 9-flowmeter, 10-metal hose, 11-ultrasonic vibration nozzle; Each cross section amplitude curve of 12-ultrasonic vibration nozzle, 13-bleeder plug, 14-coarse grain footpath abrasive material oil-feed port, particle diameter abrasive material oil-feed port among the 15-, 16-scavenging air valve, 17-fine grain abrasive material oil-feed port; The 18-oil return opening, the 19-liquid level gauge, the 20-aperture is the sieve plate of 50 μ m, the 21-aperture is the sieve plate of 10 μ m, the 22-dividing plate; The 23-valve body, 24-spool, 25-supersonic generator, 26-nickel sheet, 27-hold-down bolt; The 28-upper endpiece, 29-piezoelectric ceramics, 30-lower endpiece, 31-bolt, 32-horn.
The specific embodiment
Below in conjunction with accompanying drawing the present invention is further specified.
As shown in Figure 1, a kind of solid particle grinding fluid complex machining process and device, it is mainly by fuel tank 1, electromagnet 2; Ultrasonic vibration generator 3, fluid pressure line 4, solenoid directional control valve 5, slush pump 6; Overflow valve 7, Pressure gauge 8, flowmeter 9, metal hose 10 and ultrasonic vibration nozzle 11 constitute; Wherein fuel tank 1 is fixed on the ultrasonic vibration generator 3; Fuel tank 1 bottom is provided with electromagnet 2; Three oil-feed ports are arranged at the top, and three oil-feed ports join through fluid pressure line 4 and 5 three inlets of solenoid directional control valve, and solenoid directional control valve 5 has three inlets and an outlet; Its outlet links to each other with slush pump 6, overflow valve 7, Pressure gauge 8, flowmeter 9 and metal hose 10 through fluid pressure line 4 successively, metal hose 10 finally and ultrasonic vibration nozzle 11 join.
Fig. 2 is that positive two of fuel tank is surveyed view; Scavenging air valve 16, oil return opening 18 and 3 oil-feed ports are arranged at fuel tank 1 top; 3 oil-feed ports are respectively coarse grain footpath abrasive material oil-feed port 14, middle particle diameter abrasive material oil-feed port 15 and fine grain abrasive material oil-feed port 17; Liquid level gauge 19 is positioned at top, fuel tank 1 front side, and bleeder plug 13 is positioned at place, the fuel tank 1 right flank lower right corner.Adorning the mixed uniformly solid particle grinding fluid of grinding fluid and micro powder grade solid abrasive (particle diameter is 5 ~ 63 μ m) in the fuel tank 1; Fuel tank 1 inside by the aperture be respectively the fine grain sieve plate 21 of 5-10 μ m, 11-50 μ m, middle particle diameter sieve plate 20 is filtered into three zones to the solid particle grinding fluid; Be respectively zone, coarse grain footpath, middle particle size region and fine grain zone, wherein the oil back region communicates with zone, coarse grain footpath, and is as shown in Figure 3; Through each sieve plate screening; The abrasive size that the fine grain zone is contained is 5 ~ 10 μ m, and the abrasive size that middle particle size region contains concentrates on 11 ~ 50 μ m, and the abrasive size that zone, coarse grain footpath is contained concentrates on 51 ~ 63 μ m; According to different grinding needs, use the solid particle grinding fluid of zones of different.One side in middle particle size region and fine grain zone is against oil tank wall; Its excess-three side all is made up of corresponding sieve plate; As shown in Figure 3, fine grain zone sieve plate right flank and middle particle size region sieve plate left surface are 5 ~ 10mm apart from inner wall of oil tank, and the sieve plate height is inner wall of oil tank height (Fig. 4).The regional oil-feed port of oil return opening and coarse grain footpath places fuel tank 1 both sides respectively; And near oil return opening 18, be provided with two dividing plates 22; To strengthen the path of flow circulation, improve the effect of heat radiation and separation of air, the height of dividing plate 22 is 2/3 ~ 3/4 of fuel tank 1 inside wall height.Liquid level gauge 19 is positioned at the fine grain zone in the fuel tank 1, and bleeder plug 13 is positioned at bottom, zone, coarse grain footpath.Fuel tank 1 is connected in the outside, fuel tank 1 bottom surface with the electromagnet 2 of its underpart, and as shown in Figure 4, electromagnet 2 can not only firmly hold fuel tank 1, and makes the metal filings in the grinding fluid be fixed on fuel tank 1 bottom, prevents that metal filings from getting between emery wheel/workpiece with grinding fluid.Fuel tank 1 is fixed on the ultrasonic vibration generator 3 with electromagnet 2 together.
The effect of ultrasonic vibration generator 3 is that grinding fluid and abrasive material in the fuel tank 1 are mixed; It is similar to the ultrasonic stirring machine; Mainly constitute by supersonic generator 25, transducer (upper endpiece 28, lower endpiece 30 and piezoelectric ceramics between the two 29) and horn 32; Horn 32 end faces are bonded on the electromagnet 2 of fuel tank 1 bottom; Supersonic generator 25 changes industrial-frequency alternating current into supersonic frequency electric oscillation that the output of certain power is arranged, and the supersonic frequency electric oscillation converts the mechanical oscillation of same frequency to through the piezo-electric effect of transducer, and propagates in the fuel tank 1 in the solid particle grinding fluid with the form of superaudio mechanical wave; In the solid particle grinding fluid, produce the positive negative shock wave of hydraulic pressure and " cavitation " effect of high frequency, alternation, thereby grinding fluid and abrasive material in the fuel tank 1 are mixed.The ultrasonic frequency that ultrasonic vibration generator 3 is produced is 16 ~ 20kHz.
Solenoid directional control valve 5 is to be the three-position four-way valve of this design of Hydraulic System specially; The solid particle grinding fluid that control contains the different-grain diameter abrasive material gets into hydraulic system, its structure chart, fundamental diagram respectively like Fig. 5, shown in 6, the P mouth is outlet; A, B, C are inlets; The A mouth links to each other with fuel tank 1 coarse grain footpath abrasive material oil-feed port 14, and the B mouth links to each other with middle particle diameter abrasive material oil-feed port 15, and the C mouth links to each other with fine grain abrasive material oil-feed port 17.When spool 24 was in the diagram meta, port P and B communicated, and port A and C close, and the solid particle grinding fluid of particle diameter abrasive material (particle diameter is 11 ~ 50 μ m) gets into hydraulic system in containing this moment; When spool 24 was shifted to left end, port P and A communicated, and port B and C close, and the solid particle grinding fluid that contains seedy footpath abrasive material (particle diameter is 51 ~ 63 μ m) this moment gets into hydraulic system; When spool was shifted to right-hand member, port P and C communicated, and port A and B close, and the solid particle grinding fluid that contains fine grain abrasive material (particle diameter is 5 ~ 10 μ m) this moment gets into hydraulic system; Solenoid directional control valve sequence of movement table is as shown in table 1.
Table 1 solenoid directional control valve sequence of movement table
Slush pump 6 is power parts of this hydraulic system, compares with common hydraulic pump, and it more can bear the impact of abrasive material in the grinding fluid; It is constant that overflow valve 7 can be kept system pressure, can play overload protective function to system again; Pressure gauge 8 is used for measuring system pressure; Flowmeter 9 is used to measure the fluid pressure line flow; But metal hose 10 free bends adopt metal hose to be connected between fluid pressure line 4 and ultrasonic vibration nozzle 11 to be in order to cushion when emery wheel carried out dressing 11 vibrations of ultrasonic vibration nozzle the influence of fluid pressure line are kept hydraulic system and stablized.Fluid pressure line 4 plays the connection effect, and it need use wear-resisting made, like pottery, Monel metal etc.
The structure of ultrasonic vibration nozzle 11 is as shown in Figure 7.It mainly is made up of supersonic generator 25, transducer (comprising upper endpiece 28, lower endpiece 30 and piezoelectric ceramics between the two 29) and horn 32.Supersonic generator 25 changes industrial-frequency alternating current into supersonic frequency electric oscillation that certain power output is arranged, and its frequency is 16 ~ 20kHz.Transducer converts the high-frequency electrical vibration to mechanical oscillation, and piezoelectric ceramics 29 is important component parts of transducer, and two piezoelectric ceramics 29 stack, and is anodal in the centre, and negative pole is at upside, and warp end block 28,30 usefulness hold-down bolts 27 up and down compresses.Convenient for conductive lead wire, be clipped on the positive and negative electrode as wiring end sheet with nickel sheet 26.Horn 32 downsides are tapered, and its effect is the amplitude expansion with mechanical oscillation.Transducer and horn couple together through bolt 31.This ultrasonic vibration nozzle is holed on horn 32 taper seats and lower surface, and inside is hollow structure, and is as shown in Figure 7, and wherein the cross section of spray orifice II is a rectangle, and along short transverse, width does not become 2 ~ 5mm, and length becomes big gradually.Horn 32 integrates with nozzle, and fluid pressure line 4, metal hose 10 adopt successively with horn 32 and be threaded, the solid particle grinding fluid finally through the interior holes entering emery wheel of horn 32 between the workpiece.Horn 32 adopts the ceramic material manufacturing, makes it can bear the wearing and tearing that abrasive material brings in the solid particle grinding fluid, improves the service life of ultrasonic vibration nozzle.25 of supersonic generators are switched on when solid particle grinding fluid dressing emery wheel, for solid particle grinding fluid dressing emery wheel provides enough energy, when carrying out plain grinding and during to the workpiece polishing, supersonic generator 25 is not worked.
Fig. 7 has provided each cross section amplitude curve 12 of ultrasonic vibration nozzle in the supersonic generator course of work.When ultrasonic wave from an end of horn 32 when the other end is propagated, wave reflection will take place in the end of horn 32.So in limited horn 32, physical presence same cycle, same amplitude, two opposite ripples of the direction of propagation, these two identical ripples from opposite direction can with, will produce wave interference.When horn 32 length met a certain rule, some some position in wave process was constant all the time on the horn 32, and its amplitude is zero (for node), and other amplitude maximums, its amplitude is the twice (for antinode) of former amplitude.Be illustrated in fig. 8 shown below, x representes horn 32 any 1 b at a distance of the distance of ultrasonic wave incident end, and then the incidence wave displacement that causes the b point to depart from the equilbrium position is a
1, the displacement that back wave causes the b point to depart from the equilbrium position is a
2, then have
And two resultant displacements that b that ripple causes is ordered are a
r
X in the formula---the b point is apart from the distance of incident end;
The wavelength of λ---vibration;
The cycle of T---vibration;
The amplitude of A---vibration;
The a certain moment of t---vibration.
Can know by following formula:
When
The time, a
rMaximum, the b point is an antinode
K is a positive integer in the formula, k=0, and 1,2,3,
In order to make horn 32 be in the peak swing resonance state, should horn 32 be designed to the integral multiple of half-wavelength; And fixedly the fulcrum of horn 32 should be selected in the node place in the vibration processes, and this point is not vibrated.
The available following formula of relation between ultrasonic propagation velocity c, wavelength X and the frequency f is represented:
In order to obtain maximum ultrasonic intensity, the transducer length of the ultrasonic vibration nozzle of this device, promptly piezoelectric ceramics 29 adds that the length of lower endpiece 30 is the integral multiple of sound wave half-wavelength.The length of horn 32 also is the integral multiple of sound wave half-wavelength.As shown in Figure 7, the A point place amplitude on the amplitude curve 12 is zero, and horn 32 just is fixed on the grinding machine on this cross section.B point on the amplitude curve is an antinode; This cross section is corresponding to the top of laterally advancing hole I in the horn 32; When emery wheel was carried out dressing, ultrasonic vibration was done in the cross section here, forced the abrasive material that suspends in the working solution with very big speed and acceleration impinging sand wheel surface; Remove the bond between the emery wheel abrasive material, reach the purpose of dressing emery wheel.Meanwhile, grinding fluid receives laterally to advance the ultrasonic vibration effect of I top, hole and the high frequency hydraulic shock ripple that produces has also been strengthened the dressing to emery wheel.
Why horn 32 can enlarge amplitude, is owing to be constant (omitting propagation loss) through its vibrational energy in each cross section, and the little local energy-flux density in cross section is big.By following formula
The amplitude of A in the formula---vibration;
J---energy-flux density;
ρ---Media density;
C---spread speed;
The circular frequency of ω---vibration.
Energy-flux density J be proportional to amplitude A square, so the cross section is more little, energy-flux density is just big more, vibration amplitude is also just big more.For horn 32, ρ, c, ω are definite value, and the ratio of control its underpart circular cone cross section and the area of top cylindrical cross-section has also just changed the ratio of the energy-flux density J of corresponding position, thereby changed the multiplication factor of amplitude A.The horn 32 top cylindrical cross-section of this device are long-pending to be equated with the cross-sectional area of transducer end block, and control horn 32 lower cone cross-sectional areas make circular cone lower surface amplitude amplify 1.2 ~ 2.6 times.
In the zones of different in the fuel tank 1, the micro powder grade solid abrasive of different-grain diameter evenly mixes with grinding fluid.According to the grinding needs, can select the solid particle grinding fluid of zones of different.Said solid particle comprises aluminium oxide, carborundum, silicon nitride, diamond, cubic boron nitride abrasive materials.The mass fraction of abrasive material and grinding fluid is 2% ~ 15%.This hydraulic system can realize four functions in grinding process; Both can be used for workpiece is carried out plain grinding (comprising corase grind, half correct grinding and correct grinding), polishing; Can be used to that again emery wheel is carried out online dressing and promptly remove the bond between the wheel face abrasive material, in to workpiece grinding, polishing process, can also play enhanced heat exchange and certain lubrication simultaneously.The function of its enhanced heat exchange is made description below: can be known that by the enhanced heat exchange theory heat-transfer capability of solid is much larger than liquids and gases, the thermal conductivity factor of solid material is than the big several magnitude of fluent material under the normal temperature.The thermal conductivity factor of liquid that is suspended with solids is than neat liquid big tens times even hundreds of times.In grinding fluid, add solids, can significantly increase the thermal conductivity factor of fluid media (medium), improve the ability of convective heat transfer, greatly remedy neat liquid cooling capacity defect of insufficient.In addition, the micro powder grade solid abrasive also has tribological properties such as special antiwear and reducing friction and high bearing capacity aspect lubricated and the tribology.From the above mentioned, a cover hydraulic system can be accomplished multinomial work, has realized multi-functional integrated.
In addition, need to prove, when workpiece is carried out plain grinding and polishing, supersonic generator 25 no powers, promptly ultrasonic vibration nozzle 11 does not vibrate, and it just plays the effect of nozzle; When emery wheel is carried out dressing; Supersonic generator 25 is just switched on; With very big speed and acceleration impinging sand wheel surface, remove the bond between the wheel face abrasive material by means of the abrasive material that suspends in the ultrasonic vibration nozzle 11 solid particles grinding fluids, carry out online dressing emery wheel.
Use solid particle grinding fluid complex machining device to carry out in plain grinding, polishing and the plain grinding process following to the operating process of emery wheel dressing to workpiece:
1, workpiece is carried out plain grinding.
(1) electromagnet 2 energisings make it firmly hold fuel tank;
(2) ultrasonic vibration generator 3 energisings mix grinding fluid and abrasive material in the fuel tank;
(3) adjust ultrasonic vibration nozzle 11 angles;
(4) oil pressure relief of adjusting overflow valve 7 makes it be set to 0.4 ~ 0.5MPa.
(5) 2DT of solenoid directional control valve 5 gets electricly, and spool is positioned at the right side, and the solid particle grinding fluid in the fuel tank fine grain zone (abrasive size is 5 ~ 10 μ m) is connected with slush pump through pipeline;
(6) workpiece location, clamping start emery wheel and slush pump 6, and the solid particle grinding fluid is through solenoid directional control valve 5, slush pump
6, flowmeter 9, metal hose 10, ultrasonic vibration nozzle 11 get into emery wheels between the workpiece, can carry out plain grinding.
(7) in the plain grinding process, as workpiece surface roughness R
aWhen being 3.2 ~ 1.6 μ m, promptly finish plain grinding, begin workpiece is carried out polishing.
2, workpiece is carried out polishing.
(8) the 2DT dead electricity of solenoid directional control valve 5, spool is positioned at the centre position, and the solid particle grinding fluid in the particle size region in the fuel tank (abrasive size is 11 ~ 50 μ m) is connected with slush pump through pipeline;
(9) emery wheel stops to cut feeding, regulates other grinding parameters, and the solid particle grinding fluid of particle diameter abrasive material gets into grinding area in containing under the emery wheel drag interaction, begins workpiece is carried out polishing.
(10) after polishing finishes, close slush pump 6, ultrasonic vibration acoustical generator 3, electromagnet 2 successively.
3, in the plain grinding process to the online dressing of emery wheel.
In the plain grinding process, if the emery wheel blunt, the surface quality of workpiece and precision all can descend, and need carry out online dressing this moment to emery wheel, remove the bond between abrasive material.Here follow the step of in the operating process 1 workpiece being carried out grinding
(1) ~ (6) continue the operating procedure of explanation dressing:
(7) during dressing, stop emery wheel earlier, close slush pump 6;
(8) the adjustment nozzle location make nozzle perpendicular to the emery wheel outer round surface, and to make the distance of nozzle and emery wheel outer round surface is 5 ~ 10mm;
(9) 1DT of solenoid directional control valve 5 gets electricly, and spool is positioned at the left side, and the solid particle grinding fluid in the fuel tank coarse grain footpath zone (abrasive size is 51 ~ 63 μ m) is connected with slush pump through pipeline;
(10) start emery wheel, grinding wheel speed is too not high, and speed is 20 ~ 60r/min;
(11) open slush pump 6, make the solid particle grinding fluid that contains coarse grain footpath abrasive material get into solenoid directional control valve 5, slush pump 6, flowmeter 9, metal hose 10, ultrasonic vibration nozzle 11, vertically spray to the emery wheel cylindrical;
(12) supersonic generator 25 energisings make ultrasonic vibration nozzle 11 begin vibration, for solid particle grinding fluid dressing emery wheel provides energy;
When (13) dressing finishes, close slush pump 6, supersonic generator 25, solenoid directional control valve 5, ultrasonic vibration acoustical generator 3, electromagnet 2 successively.
Claims (8)
1. a solid particle grinding fluid complex machining device is characterized in that it comprises fuel tank, and fuel tank is connected with the ultrasonic vibration generator through electromagnet; Fuel tank internal is provided with zone, coarse grain footpath, middle particle size region and fine grain zone, and each zone is provided with the oil-feed port of a correspondence and is connected with corresponding fluid pressure line; Fluid pressure line is connected with solenoid directional control valve, and the logical fluid pressure line of electromagnetic switch valve outlet port is connected with slush pump, overflow valve, and overflow valve is connected with the ultrasonic vibration nozzle through metal hose; Ultrasonic vibration acoustical generator, electromagnet all are connected with controller.
2. solid particle grinding fluid complex machining device as claimed in claim 1 is characterized in that said fuel tank side is provided with liquid level gauge, is provided with bleeder plug in the bottom, and the top is provided with scavenging air valve; Simultaneously in fuel tank, also be provided with the oil back region, the oil back region is provided with oil return opening, and the semi-surrounding zone is formed by the dividing plate of interlaced arrangement in the oil back region; Outside this semi-surrounding zone fine grain zone, middle particle size region and zone, coarse grain footpath; Wherein, The fine grain zone is that particle diameter is that the sieve plate of 5-10um surrounds by the aperture; In particle size region be that the sieve plate of 11-50um surrounds by particle diameter, zone, coarse grain footpath be that fine grain is regional, middle particle size region remaining area outward, its abrasive size is at 51-63um.
3. solid particle grinding fluid complex machining device as claimed in claim 1; It is characterized in that said solenoid directional control valve is a three-position four-way valve, it comprises valve body and spool; On valve body, be provided with A, B, three inlets of C, be connected with the fine grain zone with zone, coarse grain footpath, middle particle size region respectively; Also being provided with a P outlet is connected with pipeline; Spool is installed in the passage of valve body, through open or close A, B, C, each mouthful of P along moving of passage.
4. solid particle grinding fluid complex machining device as claimed in claim 1 is characterized in that said ultrasonic vibration nozzle comprises upper endpiece and lower endpiece, is provided with piezoelectric ceramics between the two, and by hold-down bolt the three is compressed; Lower endpiece is connected through bolt and horn, and the horn lower end is a taper seat, and being provided with cross section in it is the spray orifice II of rectangle, and along short transverse, width does not become 2 ~ 5mm, and length becomes big gradually; Laterally advance hole I for perpendicular setting above spray orifice II; Piezoelectric ceramics is connected with the nickel sheet, and the nickel sheet is connected with supersonic generator, and supersonic generator is connected with controller.
5. solid particle grinding fluid complex machining device as claimed in claim 1 is characterized in that, also is provided with Pressure gauge, flowmeter between said overflow valve and the metal hose.
6. solid particle grinding fluid complex machining device as claimed in claim 4 is characterized in that said horn is the ceramic material horn.
7. solid particle grinding fluid complex machining device as claimed in claim 4 is characterized in that the length of said horn is the integral multiple of sound wave half-wavelength, and piezoelectric ceramics adds that the length of lower endpiece is the integral multiple of sound wave half-wavelength; Horn top cylindrical cross-section is long-pending to be equated with the cross-sectional area of lower endpiece, and control horn lower cone cross-sectional area makes circular cone lower surface amplitude amplify 1.2 ~ 2.6 times.
8. a processing technology that adopts the arbitrary described solid particle grinding fluid complex machining device of claim 1-4 is characterized in that, carries out in plain grinding, polishing and the plain grinding process following to the operating process of emery wheel dressing to workpiece:
Workpiece is carried out plain grinding:
(1) electromagnet energising makes it hold fuel tank;
(2) ultrasonic vibration generator energising mixes grinding fluid and abrasive material in the fuel tank;
(3) adjust the ultrasonic vibration nozzle angle;
(4) oil pressure relief of adjusting overflow valve makes it be set to 0.4 ~ 0.5MPa;
(5) solenoid directional control valve electric, spool moves, making fuel tank fine grain zone is that abrasive size is that the solid particle grinding fluid of 5 ~ 10 μ m is connected with slush pump through pipeline;
(6) workpiece location, clamp, start emery wheel and slush pump, the solid particle grinding fluid through solenoid directional control valve, slush pump, flowmeter, metal hose, ultrasonic vibration nozzle get into emery wheel between the workpiece, promptly carry out plain grinding; In the plain grinding process, as workpiece surface roughness R
aWhen being 3.2 ~ 1.6 μ m, promptly finish plain grinding, begin workpiece is carried out polishing; In the plain grinding process, if the emery wheel blunt, the surface quality of workpiece and precision all can descend, and need carry out online dressing this moment to emery wheel, remove the bond between abrasive material, change step (9) this moment over to;
Workpiece is carried out polishing:
(7) solenoid directional control valve dead electricity, spool is got back to the centre position, and making particle size region in the fuel tank is that abrasive size is that the solid particle grinding fluid of 11 ~ 50 μ m is connected with slush pump through pipeline;
(8) emery wheel stops to cut feeding, regulates other grinding parameters, and the solid particle grinding fluid of particle diameter abrasive material gets into grinding area in containing under the emery wheel drag interaction, begins workpiece is carried out polishing;
(9) during dressing, stop emery wheel earlier, close slush pump;
(10) the adjustment nozzle location make nozzle perpendicular to the emery wheel outer round surface, and to make the distance of nozzle and emery wheel outer round surface is 5 ~ 10mm;
(11) solenoid directional control valve 5 electric, spool moves, making zone, fuel tank coarse grain footpath is that abrasive size is that the solid particle grinding fluid of 51 ~ 63 μ m is connected with slush pump through pipeline;
(12) start emery wheel, grinding wheel speed is too not high, and speed is 20 ~ 60r/min;
(13) open slush pump, make the solid particle grinding fluid entering solenoid directional control valve, slush pump, flowmeter, metal hose, the ultrasonic vibration nozzle that contain coarse grain footpath abrasive material vertically spray to the emery wheel cylindrical;
(14) supersonic generator energising makes the ultrasonic vibration nozzle begin vibration, for solid particle grinding fluid dressing emery wheel provides energy;
When (15) dressing finishes, close slush pump, supersonic generator, solenoid directional control valve, ultrasonic vibration acoustical generator, electromagnet successively.
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