CN104972404A - Flow polishing device for manufacturing ultrasmooth surfaces by gas-liquid-solid abrasive flow - Google Patents
Flow polishing device for manufacturing ultrasmooth surfaces by gas-liquid-solid abrasive flow Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B24C3/00—Abrasive blasting machines or devices; Plants
- B24C3/32—Abrasive blasting machines or devices; Plants designed for abrasive blasting of particular work, e.g. the internal surfaces of cylinder blocks
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B24C11/00—Selection of abrasive materials or additives for abrasive blasts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B24C7/00—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts
- B24C7/0084—Equipment for feeding abrasive material; Controlling the flowability, constitution, or other physical characteristics of abrasive blasts the abrasive material being fed in a mixture of liquid and gas
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B24C9/00—Appurtenances of abrasive blasting machines or devices, e.g. working chambers, arrangements for handling used abrasive material
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Abstract
本发明公开了一种能够达到原子级别材料去除效果的气液固三相磨粒流超光滑表面流体抛光装置,包括智能电气控制柜、气泵、抛光加工平台、两个伺服控制磨粒流输送泵、搅拌器、气管和磨粒流输送软管,所述气泵通过气管连接抛光加工平台,所述抛光加工平台通过磨粒流输送软管与两个伺服控制磨粒流输送泵和搅拌器连接成一条液固二相磨粒流循环系统;整个抛光装置由所述智能电气控制柜进行加工过程控制;本发明利用气液固三相磨粒流高速湍流涡旋在循环系统中反复对所述工件进行抛光加工可以提高磨粒流的利用效率,并可以有效过滤加工残留物以较少污水排放,实现清洁加工,节约能源,绿色环保。
The invention discloses a gas-liquid-solid three-phase abrasive particle flow ultra-smooth surface fluid polishing device capable of achieving the atomic level material removal effect, including an intelligent electric control cabinet, an air pump, a polishing processing platform, and two servo-controlled abrasive particle flow delivery pumps , agitator, air pipe and abrasive flow delivery hose, the air pump is connected to the polishing processing platform through the air pipe, and the polishing processing platform is connected to two servo-controlled abrasive flow delivery pumps and agitator through the abrasive flow delivery hose A liquid-solid two-phase abrasive particle flow circulation system; the entire polishing device is controlled by the intelligent electrical control cabinet; the invention uses a gas-liquid-solid three-phase abrasive particle flow high-speed turbulent vortex to repeatedly grind the workpiece in the circulation system Polishing can improve the utilization efficiency of abrasive flow, and can effectively filter processing residues to reduce sewage discharge, realize clean processing, save energy, and be green and environmentally friendly.
Description
技术领域 technical field
本发明涉及流体超光滑表面研磨抛光装置,更具体的说,涉及一种气液固三相磨粒流超光滑表面流体抛光装置。 The invention relates to a fluid ultra-smooth surface grinding and polishing device, in particular to a gas-liquid-solid three-phase abrasive particle flow ultra-smooth surface fluid polishing device.
背景技术 Background technique
在现代光学、电子信息及薄膜科学等高新技术领域,需要在精密光学零件和功能晶体材料表面实现超光滑表面加工(Ultrasmooth Surface Manufacturing),例如软X射线光学系统、激光陀螺反射镜、高密度波分复用器、高能激光反射镜、功能光学器件、光学窗口等。 In the high-tech fields such as modern optics, electronic information and thin film science, it is necessary to realize ultra-smooth surface manufacturing (Ultrasmooth Surface Manufacturing) on the surface of precision optical parts and functional crystal materials, such as soft X-ray optical system, laser gyro mirror, high-density wave Demultiplexer, high-energy laser mirror, functional optical device, optical window, etc.
精密光学零件和功能晶体材料零件均属于高端光学装备和电子制造装备的关键零部件,而超光滑表面加工装备本身则属于超精密加工高端装备,因此,针对超光滑表面加工的关键科学问题开展研究,探索超光滑表面加工的新原理,新工艺和新装备,符合国家战略性新兴产业(高端装备制造)发展的需求。 Precision optical parts and functional crystal material parts are key components of high-end optical equipment and electronic manufacturing equipment, while ultra-smooth surface processing equipment itself belongs to ultra-precision processing high-end equipment. Therefore, research on key scientific issues of ultra-smooth surface processing , to explore new principles, new processes and new equipment for ultra-smooth surface processing, in line with the needs of the development of national strategic emerging industries (high-end equipment manufacturing).
超光滑表面除要求极低的表面粗糙度值(<1nm RMS),更重要的是必须在获得工件表面极高的形状精度同时,确保功能晶体材料工件表面晶格完整性,防止出现加工变质层和导致亚表面损伤,对于精密光学零件表面则要求极低的表面波纹度,从而实现低散射特性、高透射率及表面反射率。一般来说,超光滑表面加工为实现原子级材料去除,加工时对工件表面的作用力很小,因此属于典型的慢工出细活的加工方式,效率极低,且加工成本很高。在确保不出现加工变质层和亚表面损伤的前提下实现低成本、高效率的超光滑表面加工是精密制造领域急需解决的技术难题。 Ultra-smooth surface requires extremely low surface roughness (<1nm RMS), more importantly, it must ensure the integrity of the surface lattice of the functional crystal material workpiece surface while obtaining the extremely high shape accuracy of the workpiece surface, so as to prevent the occurrence of processing deterioration layer And lead to sub-surface damage, for the surface of precision optical parts requires extremely low surface waviness, so as to achieve low scattering characteristics, high transmittance and surface reflectivity. Generally speaking, ultra-smooth surface processing is to achieve atomic-level material removal, and the force on the surface of the workpiece is very small during processing. Therefore, it is a typical slow-work and meticulous processing method, with extremely low efficiency and high processing costs. Realizing low-cost, high-efficiency ultra-smooth surface processing without the occurrence of processing-deteriorated layers and sub-surface damage is an urgent technical problem in the field of precision manufacturing.
现有超光滑表面加工方法,总体可分为两类,一类依靠加工工具接触工件表面实现加工(如使用砂轮、砂带或其它柔性材料作为工具的磨削、抛光等),另一类则不依靠加工工具直接接触工件表面,而是利用携带微细磨粒的磨粒流的高速流动实现对工件表面的加工,可以将这一类加工方法统称为流体抛光。当前主要的磨粒流抛光加工方法主要有:挤压珩磨抛光、 磨粒水射流抛光、磁流变抛光、磁射流抛光、电流变液抛光等。这些方法利用磨粒流与加工表面接触时的壁面冲击效应,形成磨粒对表面的微切削实现表面材料去除,达到光整加工效果。 Existing ultra-smooth surface processing methods can be generally divided into two categories, one class relies on processing tools to contact the surface of the workpiece to achieve processing (such as grinding, polishing, etc. using grinding wheels, abrasive belts or other flexible materials as tools), and the other class Instead of relying on processing tools to directly contact the surface of the workpiece, the high-speed flow of the abrasive flow carrying fine abrasive particles is used to process the surface of the workpiece. This type of processing method can be collectively referred to as fluid polishing. At present, the main abrasive flow polishing processing methods mainly include: extrusion honing polishing, abrasive water jet polishing, magnetorheological polishing, magnetic jet polishing, electrorheological fluid polishing, etc. These methods use the wall impact effect when the abrasive grain flow contacts the machined surface to form micro-cutting of the abrasive grain on the surface to remove the surface material and achieve the finishing effect.
但由于上述磨粒流加工方法的固有特点,加工后很多尚不能获得满意的表面粗糙度。现有的一些流体抛光加工方法中流体相对工件表面的流速偏低且流动方向单一(以工具相对工件旋转,带动两者之间缝隙处流体流动的方法,例如磁流变抛光则属于这种情况)。这时,由于流体流速不足以达到湍流状态,一般处于层流状态,磨粒流动方向基本一致,只有与工件直接接触的表层流体处的磨粒有机会与被加工表面接触,因此真正发挥切削作用的磨粒只是流体中磨粒的极少部分,并仅从单一方向作用于凸起峰,加工效率自然不高。另外一些流体抛光加工方法中还存在流体相对工件表面的法向冲击力力过大或作用力与工件表面的夹角不合理(以磨粒水射流方式冲击工件表面的抛光方则属于这种情况)的缺陷。这时,流体流速虽可以达到很高,但磨粒冲击方向仍基本一致,冲击流与工件直接接触的面积小,若法向冲击力力过小,则加工效率很低,法向冲击力过大或作用力与工件表面的夹角不合理则可能导致表面损伤和新的不光滑表面出现,因此很难把握加工品质与加工效率的协调关系。从如今社会对超精密光学零件和功能晶体材料的广阔需求前景来考虑,解决超光滑表面精密制造的技术难题,尚需提出新的解决方法以达到原子级别的超光滑表面精密加工效果。 However, due to the inherent characteristics of the above-mentioned abrasive flow processing method, many of them cannot obtain satisfactory surface roughness after processing. In some existing fluid polishing processing methods, the flow velocity of the fluid relative to the surface of the workpiece is low and the flow direction is single (the method in which the tool rotates relative to the workpiece to drive the fluid flow in the gap between the two, such as magnetorheological polishing, belongs to this case ). At this time, because the fluid flow rate is not enough to reach a turbulent state, it is generally in a laminar flow state, and the flow direction of the abrasive grains is basically the same. Only the abrasive grains at the surface fluid in direct contact with the workpiece have the opportunity to contact the processed surface, so they really play a cutting role. The abrasive particles are only a very small part of the abrasive particles in the fluid, and only act on the raised peaks from a single direction, so the processing efficiency is naturally not high. In some other fluid polishing methods, the normal impact force of the fluid relative to the surface of the workpiece is too large or the angle between the force and the surface of the workpiece is unreasonable (this is the case for polishing methods that impact the surface of the workpiece in the form of abrasive water jets. )Defects. At this time, although the fluid flow rate can be very high, the impact direction of the abrasive particles is still basically the same, and the area of direct contact between the impact flow and the workpiece is small. If the normal impact force is too small, the processing efficiency is very low, and the normal impact force is too high. Large or unreasonable angles between the force and the surface of the workpiece may lead to surface damage and new rough surfaces, so it is difficult to grasp the coordination relationship between processing quality and processing efficiency. Considering the broad demand prospects for ultra-precision optical parts and functional crystal materials in today's society, to solve the technical problems of ultra-smooth surface precision manufacturing, it is still necessary to propose new solutions to achieve atomic-level ultra-smooth surface precision machining effects.
发明内容 Contents of the invention
本发明的目的就在于确保不出现加工变质层和亚表面损伤的前提下实现精密制造领域低成本、高效率超光滑表面加工的技术难题,提出了一种能够达到原子级别材料去除效果的气液固三相磨粒流超光滑表面流体抛光装置。 The purpose of the present invention is to realize the technical problem of low-cost and high-efficiency ultra-smooth surface processing in the field of precision manufacturing under the premise of ensuring that no processing deterioration layer and sub-surface damage occur, and proposes a gas-liquid that can achieve the effect of removing materials at the atomic level Solid three-phase abrasive flow ultra-smooth surface fluid polishing device.
本发明通过以下技术方案来实现上述目的:一种气液固三相磨粒流超光滑表面流体抛光装置,包括智能电气控制柜、气泵、抛光加工平台、两个伺服控制磨粒流输送泵、搅拌器、气管和磨粒流输送软管,所述气泵通过气管连接抛光加工平台,所述抛光加工平台通过磨粒 流输送软管与两个伺服控制磨粒流输送泵和搅拌器连接成一条液固二相磨粒流循环系统;整个抛光装置由所述智能电气控制柜进行加工过程控制。 The present invention achieves the above object through the following technical solutions: a gas-liquid-solid three-phase abrasive flow ultra-smooth surface fluid polishing device, including an intelligent electrical control cabinet, an air pump, a polishing processing platform, two servo-controlled abrasive flow delivery pumps, Stirrer, air pipe and abrasive flow delivery hose, the air pump is connected to the polishing processing platform through the air pipe, and the polishing processing platform is connected to two servo-controlled abrasive flow delivery pumps and agitator through the abrasive flow delivery hose Liquid-solid two-phase abrasive particle flow circulation system; the entire polishing device is controlled by the intelligent electrical control cabinet.
所述抛光加工平台包括机架、高精度丝杠传动系统、机架传动构件、圆盘形抛光工具、不锈钢旋转接头、气管接头、工件夹具、工件夹具安装底座和不锈钢水槽,所述不锈钢水槽安装在机架上,工件夹具安装底座固定在不锈钢水槽底部,工件夹具固定在工件夹具安装底座上;所述不锈钢水槽两侧的机架上固定有左右对称分布的高精度丝杠传动系统,两个高精度丝杠传动系统连接机架传动构件并驱动所述机架传动构件上下运动;圆盘形抛光工具安装在所述工件夹具正上方的机架传动构件上;所述两个高精度丝杠传动系统通过驱动所述机架传动构件上下运动带动所述圆盘形抛光工具在所述不锈钢水槽中上下运动。 The polishing processing platform includes a frame, a high-precision screw transmission system, a frame transmission member, a disc-shaped polishing tool, a stainless steel rotary joint, a gas pipe joint, a workpiece fixture, a workpiece fixture mounting base and a stainless steel water tank, and the stainless steel water tank is installed On the frame, the mounting base of the workpiece fixture is fixed on the bottom of the stainless steel water tank, and the workpiece fixture is fixed on the mounting base of the workpiece fixture; the frame on both sides of the stainless steel water tank is fixed with high-precision screw drive systems symmetrically distributed left and right, two The high-precision lead screw transmission system connects the frame transmission component and drives the frame transmission component to move up and down; the disc-shaped polishing tool is installed on the frame transmission component directly above the workpiece fixture; the two high-precision lead screws The transmission system drives the disc-shaped polishing tool to move up and down in the stainless steel water tank by driving the frame transmission member to move up and down.
所述圆盘形抛光工具与被加工工件的上表面形成大面积的微距缝隙,圆盘形抛光工具设有内腔,圆盘形抛光工具的顶面设有与内腔连通的用于注入抛光磨粒的磨粒注入通道,所述磨粒注入通道通过不锈钢旋转接头连接磨粒流输送软管并通过磨粒流输送软管与两个伺服控制磨粒流输送泵连通;所述圆盘形抛光工具的侧面还设有均匀分布的至少两个气流注入通道,所述气流注入通道与所述内腔连通并用于向所述内腔注入高速气流,所述气流注入通道通过气管接头连接气管并通过气管连接气泵。 The disc-shaped polishing tool and the upper surface of the workpiece to be processed form a large-area macro-distance gap, the disc-shaped polishing tool is provided with an inner cavity, and the top surface of the disc-shaped polishing tool is provided with a hole for injecting into the inner cavity. Abrasive grain injection channel for polishing abrasive grains, the abrasive grain injection channel is connected to the abrasive grain flow delivery hose through a stainless steel rotary joint and communicated with two servo-controlled abrasive grain flow delivery pumps through the abrasive grain flow delivery hose; the disc The side of the shaped polishing tool is also provided with at least two airflow injection passages evenly distributed, the airflow injection passage communicates with the inner chamber and is used to inject high-speed airflow into the inner chamber, and the airflow injection passage is connected to the air pipe through the air pipe joint And connect the air pump through the trachea.
进一步的,所述磨粒注入通道最优数目为三条,气流注入通道最优数目为三条。 Further, the optimal number of abrasive particle injection channels is three, and the optimal number of airflow injection channels is three.
进一步的,所述高精度丝杠传动系统包括步进电机、丝杠和直线导轨,丝杠和直线导轨竖直安装,所述丝杠的一端通过联轴器连接步进电机,步进电机固定在所述机架上;所述丝杠的另一端通过轴承座固定在所述机架上;所述直线导轨的两端直接固定在所述机架上;所述机架传动构件连接丝杠和直线导轨并受所述步进电机的驱动在所述不锈钢水槽内上下运动。 Further, the high-precision lead screw transmission system includes a stepping motor, a lead screw and a linear guide rail, the lead screw and the linear guide rail are installed vertically, one end of the lead screw is connected to the stepping motor through a coupling, and the stepping motor is fixed On the frame; the other end of the lead screw is fixed on the frame through a bearing seat; the two ends of the linear guide rail are directly fixed on the frame; the frame transmission member is connected to the lead screw And the linear guide rail and is driven by the stepping motor to move up and down in the stainless steel water tank.
进一步的,所述圆盘形抛光工具顶面还设有树脂玻璃视窗,所述树脂玻璃视窗为由树脂材料制成的无色透明圆形玻璃。通过所述树脂玻璃视窗可以视觉观察所述圆盘形抛光工具内 腔中的流体运动,且所述树脂玻璃视窗具有良好的机械加工性能,通过螺钉固定安装在圆盘形抛光工具的顶面,提高了装置的稳固性。 Further, the top surface of the disc-shaped polishing tool is also provided with a resin glass window, and the resin glass window is a colorless transparent circular glass made of resin material. The fluid movement in the inner cavity of the disc-shaped polishing tool can be visually observed through the resin glass window, and the resin glass window has good machining performance, and is fixedly installed on the top surface of the disc-shaped polishing tool by screws, The stability of the device is improved.
进一步的,所述工件夹具安装底座的外表面采用镀铬处理工艺进行处理。该工艺提高了工件夹具安装底座的抗腐蚀、抗锈蚀性能,进而提高了装置的使用寿命,防止磨粒流被铁锈等杂质污染。 Further, the outer surface of the mounting base of the workpiece fixture is treated with a chrome-plating process. This process improves the anti-corrosion and anti-corrosion properties of the workpiece fixture installation base, thereby improving the service life of the device and preventing the abrasive grain flow from being polluted by impurities such as rust.
进一步的,所述智能电气控制柜包括PLC智能控制器、继电器、伺服电机驱动器、各类传感器和其他电器元器件,所述智能电气控制柜通过所述各类传感器精确的感知与之关联设备的工作状态,及时发出指令对与之关联的设备进行高精度控制。 Further, the intelligent electrical control cabinet includes PLC intelligent controllers, relays, servo motor drivers, various sensors and other electrical components, and the intelligent electrical control cabinet accurately perceives the parameters of the associated equipment through the various sensors. In the working state, issue instructions in time to perform high-precision control on the equipment associated with it.
进一步的,气泵的容量为32升、最大压力为2兆帕,所述气泵通过气管向所述圆盘形抛光工具中注入高速气流,进而驱动圆盘形抛光工具内的液固二相磨粒流高速旋转以达到湍流状态,形成气液固三相磨粒流高速湍流涡旋。 Further, the capacity of the air pump is 32 liters, and the maximum pressure is 2 MPa. The air pump injects high-speed airflow into the disc-shaped polishing tool through the air pipe, and then drives the liquid-solid two-phase abrasive particles in the disc-shaped polishing tool. The flow rotates at a high speed to achieve a turbulent state, forming a high-speed turbulent vortex of a gas-liquid-solid three-phase abrasive particle flow.
进一步的,所述气管为直径为八分的硬质塑料管。气管具有良好的抗弯折性能,保证了所述气流注入通道内的高速气流的稳定性和每一条多向气流注入通道内气流的流速和压力的一致性。 Further, the trachea is a hard plastic tube with a diameter of eight quarters. The trachea has good bending resistance, which ensures the stability of the high-speed airflow in the airflow injection channel and the consistency of the flow velocity and pressure of each multi-directional airflow injection channel.
进一步的,所述磨粒流输送软管为内嵌钢丝的透明橡胶软管。磨粒流输送软管具有十分良好的抗弯折性能,防止高速流体在通过弯折处会产生扰流等复杂变化,进而保证了注入所述圆盘形抛光工具内腔中所述液固二相磨粒流的稳定性。 Further, the abrasive particle flow conveying hose is a transparent rubber hose embedded with steel wires. The abrasive particle flow delivery hose has very good bending resistance, which prevents complex changes such as turbulence when the high-speed fluid passes through the bend, thereby ensuring that the liquid-solid phase injected into the inner cavity of the disc-shaped polishing tool phase abrasive flow stability.
本发明的有益效果在于: The beneficial effects of the present invention are:
1)利用非接触式圆盘形抛光工具在工件表面形成大面积微距缝隙,可以对大面积平面或曲率变化缓和的大面积曲面工件进行高效原子级材料去除,表面粗糙度达到Rq1纳米以下,且光学波纹和表面损伤情况符合超光滑表面加工要求,加工效率较现有技术提高一倍以上。 1) Using a non-contact disc-shaped polishing tool to form large-area micro-pitch gaps on the surface of the workpiece, it can efficiently remove materials at the atomic level for large-area flat or large-area curved workpieces with moderate curvature changes, and the surface roughness can reach below Rq1 nanometers. Moreover, the optical corrugation and surface damage meet the requirements of ultra-smooth surface processing, and the processing efficiency is more than doubled compared with the prior art.
2)气液固三相磨粒流中的微尺寸气泡在掺合量和流速的控制下可以以适当的方式溃灭,溃灭过程中对附近的磨粒产生加速推动作用,大幅度提高了磨粒产生的加工作用的几率。 2) The micro-sized bubbles in the gas-liquid-solid three-phase abrasive flow can collapse in an appropriate manner under the control of the blending amount and flow rate. During the collapse process, the nearby abrasive particles can be accelerated and pushed, which greatly improves the The probability of machining action produced by abrasive particles.
3)本发明可以提升超精密加工装置的研发技术基础,促进我国超精密加工装置的发展。 3) The present invention can improve the research and development technology basis of ultra-precision processing devices, and promote the development of ultra-precision processing devices in China.
4)利用气液固三相磨粒流高速湍流涡旋在循环系统中反复对所述工件进行抛光加工可以提高磨粒流的利用效率,并可以有效过滤加工残留物以较少污水排放,实现清洁加工,节约能源,绿色环保。 4) Using gas-liquid-solid three-phase abrasive flow high-speed turbulent vortex to repeatedly polish the workpiece in the circulation system can improve the utilization efficiency of abrasive flow, and can effectively filter processing residues to reduce sewage discharge, and realize Clean processing, energy saving, green and environmental protection.
附图说明 Description of drawings
图1是本发明一种气液固三相磨粒流超光滑表面流体抛光装置的结构示意图。 Fig. 1 is a schematic structural view of a gas-liquid-solid three-phase abrasive particle flow ultra-smooth surface fluid polishing device of the present invention.
图2是本发明圆盘形抛光装置的结构示意图。 Fig. 2 is a schematic structural view of a disc-shaped polishing device of the present invention.
图3是本发明圆盘形抛光装置的俯视图。 Fig. 3 is a top view of the disc-shaped polishing device of the present invention.
图4是本发明抛光加工平台的结构示意图。 Fig. 4 is a schematic structural view of the polishing processing platform of the present invention.
图中,1-智能电气控制柜、2-抛光加工平台、3(5)-伺服控制磨粒流输送泵、4-搅拌器、6-磨粒流输送软管、7-气管、8-气泵、9-工件、10-有效抛光区、11-磨粒、12-气液固三相磨粒流高速湍流涡旋、13-树脂玻璃视窗、21-机架、22-轴承座、23-直线导轨、24-丝杠螺母、25-丝杠、26-联轴器、27-步进电机、28-机架传动构件、29-圆盘形抛光工具、211-不锈钢旋转接头、212-气管接头、214-工件夹具、215-工件夹具安装底座、216-不锈钢水槽。 In the figure, 1-intelligent electrical control cabinet, 2-polishing processing platform, 3(5)-servo-controlled abrasive flow delivery pump, 4-stirrer, 6-abrasive flow delivery hose, 7-air pipe, 8-air pump , 9-workpiece, 10-effective polishing area, 11-abrasive, 12-gas-liquid-solid three-phase abrasive flow high-speed turbulent vortex, 13-resin glass window, 21-frame, 22-bearing seat, 23-line Guide rail, 24-lead screw nut, 25-lead screw, 26-coupling, 27-stepper motor, 28-frame transmission component, 29-disc-shaped polishing tool, 211-stainless steel rotary joint, 212-trachea joint , 214-workpiece fixture, 215-workpiece fixture installation base, 216-stainless steel sink. the
具体实施方式 Detailed ways
下面结合附图对本发明作进一步说明: The present invention will be further described below in conjunction with accompanying drawing:
如图1~4所示,一种气液固三相磨粒流超光滑表面流体抛光装置,包括智能电气控制柜1、气泵8、抛光加工平台2、两个伺服控制磨粒流输送泵3、5、搅拌器4、气管7和磨粒流输送软管6,所述气泵8通过气管7连接抛光加工平台2,所述抛光加工平台2通过磨粒流输送软管6与两个伺服控制磨粒流输送泵3、5和搅拌器4连接成一条液固二相磨粒流循环系统;整个抛光装置由所述智能电气控制柜1进行加工过程控制; As shown in Figures 1 to 4, a gas-liquid-solid three-phase abrasive flow ultra-smooth surface fluid polishing device includes an intelligent electrical control cabinet 1, an air pump 8, a polishing processing platform 2, and two servo-controlled abrasive flow delivery pumps 3 , 5, agitator 4, gas pipe 7 and abrasive grain flow conveying hose 6, described air pump 8 is connected polishing processing platform 2 through gas pipe 7, and described polishing processing platform 2 is connected with two servo control via abrasive grain flow conveying flexible pipe 6 Abrasive flow delivery pumps 3, 5 and agitator 4 are connected to form a liquid-solid two-phase abrasive flow circulation system; the entire polishing device is controlled by the intelligent electrical control cabinet 1;
所述抛光加工平台2包括机架21、高精度丝杠传动系统、机架传动构件28、圆盘形抛光工具29、不锈钢旋转接头211、气管接头212、工件夹具、工件夹具安装底座215和不锈钢水槽216,所述不锈钢水槽216安装在机架21上,工件夹具安装底座215固定在不锈钢水槽 216底部,工件夹具固定在工件夹具安装底座215上;所述不锈钢水槽216两侧的机架21上固定有左右对称分布的高精度丝杠传动系统,两个高精度丝杠25传动系统连接机架传动构件28并驱动所述机架传动构件28上下运动;圆盘形抛光工具29安装在所述工件夹具正上方的机架传动构件28上;所述两个高精度丝杠25传动系统通过驱动所述机架传动构件28上下运动带动所述圆盘形抛光工具29在所述不锈钢水槽216中上下运动; The polishing processing platform 2 includes a frame 21, a high-precision lead screw transmission system, a frame transmission member 28, a disc-shaped polishing tool 29, a stainless steel rotary joint 211, a gas pipe joint 212, a workpiece fixture, a workpiece fixture mounting base 215 and a stainless steel Water tank 216, described stainless steel water tank 216 is installed on the frame 21, and workpiece fixture mounting base 215 is fixed on stainless steel water tank 216 bottoms, and workpiece clamp is fixed on the workpiece fixture mounting base 215; On the frame 21 of described stainless steel water tank 216 two sides A high-precision lead screw transmission system with left-right symmetrical distribution is fixed, and two high-precision lead screws 25 transmission systems are connected to the frame transmission member 28 and drive the frame transmission member 28 to move up and down; the disc-shaped polishing tool 29 is installed on the On the frame transmission member 28 directly above the workpiece fixture; the two high-precision lead screw 25 transmission systems drive the disc-shaped polishing tool 29 in the stainless steel water tank 216 by driving the frame transmission member 28 to move up and down up and down movement;
所述圆盘形抛光工具29与被加工工件9的上表面形成大面积的微距缝隙,圆盘形抛光工具29设有内腔,圆盘形抛光工具29的顶面设有与内腔连通的用于注入抛光磨粒的磨粒注入通道,所述磨粒注入通道通过不锈钢旋转接头211连接磨粒流输送软管6并通过磨粒流输送软管6与两个伺服控制磨粒流输送泵3、5连通;所述圆盘形抛光工具29的侧面还设有均匀分布的至少两个气流注入通道,所述气流注入通道与所述内腔连通并用于向所述内腔注入高速气流,所述气流注入通道通过气管接头212连接气管7并通过气管7连接气泵8。。 Described disc-shaped polishing tool 29 and the upper surface of processed workpiece 9 form the micro-distance gap of large area, and disc-shaped polishing tool 29 is provided with inner cavity, and the top surface of disc-shaped polishing tool 29 is provided with and communicates with the inner cavity. The abrasive grain injection channel for injecting polishing abrasive grains, the abrasive grain injection channel is connected to the abrasive grain flow conveying hose 6 through the stainless steel rotary joint 211 and is conveyed with two servo-controlled abrasive grain flow through the abrasive grain flow conveying hose 6 The pumps 3 and 5 communicate; the side of the disc-shaped polishing tool 29 is also provided with at least two airflow injection channels evenly distributed, and the airflow injection channels communicate with the inner cavity and are used to inject high-speed airflow into the inner cavity , the gas flow injection channel is connected to the air pipe 7 through the air pipe joint 212 and connected to the air pump 8 through the air pipe 7 . .
所述磨粒注入通道最优数目为三条,气流注入通道最优数目为三条。 The optimal number of abrasive particle injection channels is three, and the optimal number of airflow injection channels is three.
所述高精度丝杠25传动系统包括步进电机27、丝杠25和直线导轨23,丝杠25和直线导轨23竖直安装,所述丝杠25的一端通过联轴器26连接步进电机27,步进电机27固定在所述机架21上;所述丝杠25的另一端通过轴承座22固定在所述机架21上;所述直线导轨23的两端直接固定在所述机架21上;所述机架传动构件28连接丝杠25和直线导轨23并受所述步进电机27的驱动在所述不锈钢水槽216内上下运动。 The transmission system of the high-precision leading screw 25 includes a stepper motor 27, a leading screw 25 and a linear guide rail 23, the leading screw 25 and the linear guide rail 23 are installed vertically, and one end of the leading screw 25 is connected to the stepping motor through a shaft coupling 26 27. The stepper motor 27 is fixed on the frame 21; the other end of the screw 25 is fixed on the frame 21 through the bearing seat 22; the two ends of the linear guide rail 23 are directly fixed on the frame 21. On the frame 21; the frame transmission member 28 connects the lead screw 25 and the linear guide rail 23 and is driven by the stepping motor 27 to move up and down in the stainless steel water tank 216. the
所述圆盘形抛光工具29顶面还设有树脂玻璃视窗,所述树脂玻璃视窗为由树脂材料制成的无色透明圆形玻璃。 The top surface of the disc-shaped polishing tool 29 is also provided with a resin glass window, and the resin glass window is a colorless transparent circular glass made of resin material.
所述工件夹具安装底座215的外表面采用镀铬处理工艺进行处理。 The outer surface of the workpiece fixture mounting base 215 is treated with chrome plating.
所述智能电气控制柜1包括PLC智能控制器、继电器、伺服电机驱动器、各类传感器和其他电器元器件,所述智能电气控制柜1通过所述各类传感器精确的感知与之关联设备的工作状态,及时发出指令对与之关联的设备进行高精度控制。 The intelligent electrical control cabinet 1 includes PLC intelligent controllers, relays, servo motor drivers, various sensors and other electrical components, and the intelligent electrical control cabinet 1 accurately perceives the work of the associated equipment through the various sensors State, and timely issue instructions to perform high-precision control on the associated equipment.
气泵8的容量为32升、最大压力为2兆帕。所述气泵8通过气管7向所述圆盘形抛光工具29中注入高速气流,进而驱动圆盘形抛光工具内的液固二相磨粒流高速旋转以达到湍流状态,形成气液固三相磨粒流高速湍流涡旋12。 The capacity of the air pump 8 is 32 liters, and the maximum pressure is 2 MPa. The air pump 8 injects high-speed airflow into the disc-shaped polishing tool 29 through the air pipe 7, and then drives the liquid-solid two-phase abrasive particle flow in the disc-shaped polishing tool to rotate at a high speed to achieve a turbulent state, forming a gas-liquid-solid three-phase Abrasive flow High speed turbulent vortex12.
所述气管7为直径为八分的硬质塑料管。气管7具有良好的抗弯折性能,保证了所述气流注入通道内的高速气流的稳定性和每一条多向气流注入通道内气流的流速和压力的一致性。 Described trachea 7 is the hard plastic tube that diameter is eight minutes. The air pipe 7 has good bending resistance, which ensures the stability of the high-speed airflow in the airflow injection channel and the consistency of the flow velocity and pressure of each multi-directional airflow injection channel.
所述磨粒流输送软管6为内嵌钢丝的透明橡胶软管。磨粒流输送软管6具有十分良好的抗弯折性能,防止高速流体在通过弯折处会产生扰流等复杂变化,进而保证了注入所述圆盘形抛光工具内腔中所述液固二相磨粒流的稳定性。 The abrasive flow conveying hose 6 is a transparent rubber hose embedded with steel wires. The abrasive particle flow conveying hose 6 has very good bending resistance, which prevents complex changes such as turbulence when the high-speed fluid passes through the bend, thereby ensuring that the liquid-solid fluid injected into the inner cavity of the disc-shaped polishing tool Stability of two-phase abrasive flow.
不锈钢旋转接头211一端的公制螺纹接头旋紧固定在所述圆盘形抛光工具29上,另一端的软管接头套在所述磨粒流输送软管6内由钢丝抱箍扎紧。气管接头212一端的公制螺纹接头旋紧固定在所述圆盘形抛光工具29上,另一端的卡套式气管接头则与气管7连接。工件9安装在工件夹具214上,工件夹具214安装在工件夹具安装底座215上,其中,工件9与圆盘形抛光工具29同心安装,且两者之间间距不大于1毫米,以形成所述大面积微距缝隙。 The metric threaded joint at one end of the stainless steel rotary joint 211 is screwed and fixed on the disc-shaped polishing tool 29 , and the hose joint at the other end is sleeved in the abrasive particle flow delivery hose 6 and fastened by a steel wire hoop. The metric threaded joint at one end of the air pipe joint 212 is screwed and fixed on the disc-shaped polishing tool 29 , and the ferrule-type air pipe joint at the other end is connected with the air pipe 7 . The workpiece 9 is installed on the workpiece holder 214, and the workpiece holder 214 is installed on the workpiece holder installation base 215, wherein, the workpiece 9 and the disc-shaped polishing tool 29 are concentrically installed, and the distance between the two is not more than 1 millimeter, to form the described Large area macro gap.
该装置的具体实施步骤如下:向圆盘形抛光工具29内腔中高速注入液固二相磨粒流,其在有效抛光区10的大面积微距间隙内驱动形成气液固三相磨粒流高速湍流涡旋12,在向圆盘形抛光工具29内腔中注入液固二相磨粒流的同时,利用多向气流注入方法向圆盘形抛光工具29内腔的液固二相磨粒流中注入高速气流,高速气流沿着液固二相磨粒流的外边缘注入,提高气液固三相磨粒流高速湍流涡旋12在有效抛光区10内的旋转速度。通过视觉观察气液固三相磨粒流高速湍流涡旋12的运动规律,调节相关控制参数使所述气液固三相磨粒流高速湍流涡旋12达到最佳的工作状态进行抛光加工。进行一定时间的抛光加工后,对工件9进行测试分析,对比验证所述微尺寸气泡溃灭加速所述磨粒11对所述工件9的切削效果,进而优化抛光加工工艺方案,最后拟定具体的抛光加工工艺方案,对工件9进行抛光加工。 The specific implementation steps of the device are as follows: Inject the liquid-solid two-phase abrasive particle flow into the inner cavity of the disc-shaped polishing tool 29 at a high speed, which drives and forms the gas-liquid-solid three-phase abrasive particle in the large-area micro-pitch gap of the effective polishing area 10 Flow high-speed turbulent vortex 12, when injecting liquid-solid two-phase abrasive particle flow in disc-shaped polishing tool 29 inner chambers, utilize multi-directional air flow injection method to the liquid-solid two-phase abrasive particle flow of disc-shaped polishing tool 29 inner chambers A high-speed airflow is injected into the grain flow, and the high-speed airflow is injected along the outer edge of the liquid-solid two-phase abrasive grain flow to increase the rotation speed of the high-speed turbulent vortex 12 of the gas-liquid-solid three-phase abrasive grain flow in the effective polishing area 10 . By visually observing the movement law of the gas-liquid-solid three-phase abrasive particle flow high-speed turbulent vortex 12, adjusting relevant control parameters to make the gas-liquid-solid three-phase abrasive particle flow high-speed turbulent vortex 12 reach the best working state for polishing. After polishing for a certain period of time, test and analyze the workpiece 9, compare and verify that the collapse of the micro-sized bubbles accelerates the cutting effect of the abrasive grains 11 on the workpiece 9, optimize the polishing process plan, and finally draw up a specific Polishing process scheme, the workpiece 9 is polished.
工作时,智能电气控制柜1先关闭气泵8、伺服控制磨粒流输送泵3、5和搅拌器4,首先往不锈钢水槽216中加入一定量抛光液和磨粒形成液固二相磨粒流6,之后由智能电气控制柜1控制开启抛光加工平台2中的步进电机27,进而驱动安装在机架21上的圆盘形抛光工具29高精度运动,使圆盘形抛光工具29运动到圆盘形抛光工具底面5与工件9上表面距离不大于1毫米处。此时,再由智能电气控制柜1控制开启伺服控制磨粒流输送泵3、5和搅拌器4,最后由智能电气控制柜1控制开启气泵8,向圆盘形抛光工具内腔4中注入高速气流;通过智能电气控制柜1调节各种设备的工作参数,从树脂玻璃视窗13视觉观察圆盘形抛光工具内腔4内磨粒流的运动情况,调节到最佳的加工状态进行抛光加工作业。 When working, the intelligent electrical control cabinet 1 first turns off the air pump 8, the servo-controlled abrasive flow delivery pumps 3, 5 and the agitator 4, and first adds a certain amount of polishing liquid and abrasive particles into the stainless steel water tank 216 to form a liquid-solid two-phase abrasive flow 6. After that, the stepper motor 27 in the polishing processing platform 2 is controlled by the intelligent electrical control cabinet 1, and then the disc-shaped polishing tool 29 mounted on the frame 21 is driven to move with high precision, so that the disc-shaped polishing tool 29 moves to The distance between the bottom surface 5 of the disc-shaped polishing tool and the upper surface of the workpiece 9 is not greater than 1 mm. At this time, the servo-controlled abrasive flow conveying pumps 3, 5 and agitator 4 are controlled by the intelligent electrical control cabinet 1, and finally the air pump 8 is controlled by the intelligent electrical control cabinet 1, and injected into the inner cavity 4 of the disc-shaped polishing tool High-speed airflow; adjust the working parameters of various equipment through the intelligent electrical control cabinet 1, visually observe the movement of the abrasive grain flow in the inner cavity 4 of the disc-shaped polishing tool from the resin glass window 13, and adjust to the best processing state for polishing Operation.
抛光装置的搭建过程: The construction process of the polishing device:
①伺服控制磨粒流输送泵的选择: ①Selection of servo-controlled abrasive flow delivery pump:
伺服控制磨粒流输送泵的选择是抛光装置搭建的核心问题。对于本发明来说,伺服控制磨粒流输送泵应该满足两个基本条件:输送泵的最大流量和最大出口压力等技术参数应该为能够在多向液固二相磨粒流注入通道内产生湍流的基本要求的1.5倍;输送泵能够输送含有固体磨粒颗粒的二相流体。 The selection of the servo-controlled abrasive flow delivery pump is the core issue in the construction of the polishing device. For the present invention, the servo-controlled abrasive particle flow delivery pump should meet two basic conditions: the technical parameters such as the maximum flow rate and the maximum outlet pressure of the delivery pump should be able to generate turbulence in the multi-directional liquid-solid two-phase abrasive flow injection channel 1.5 times the basic requirement; the transfer pump can transfer two-phase fluid containing solid abrasive particles.
多向液固二相磨粒流注入通道的水力直径为d=0.032m The hydraulic diameter of the multi-directional liquid-solid two-phase abrasive flow injection channel is d=0.032m
对于管道流动,其层流到湍流的临届雷诺数Recr应在2100~4000之间,既当雷诺数Re小于2000时为层流状态,当雷诺数Re大于4000是为湍流状态。取Recr的浮动区间上限4000,管道流体雷诺数与流速、水力直径成正比,与流体粘度成反比。已知室温下水的运动粘度,这时可以得到多向液固二相磨粒流注入通道产生湍流临界流速与流量; For pipeline flow, the temporary Reynolds number Recr from laminar flow to turbulent flow should be between 2100 and 4000, that is, when the Reynolds number Re is less than 2000, it is a laminar flow state, and when the Reynolds number Re is greater than 4000, it is a turbulent flow state. Taking the upper limit of the floating interval of Recr as 4000, the pipeline fluid Reynolds number is directly proportional to flow velocity and hydraulic diameter, and inversely proportional to fluid viscosity. Knowing the kinematic viscosity of water at room temperature, the critical flow velocity and flow rate of the turbulent flow generated by the multi-directional liquid-solid two-phase abrasive flow injection channel can be obtained;
可以选择泵的型号,初步选择为意大利SEKO品牌的MS1系列机械隔膜计量泵,流量为5.5~530升/小时,最大压力为10bar,其最大雷诺数完全可以满足湍流充分发生的要求。 You can choose the pump model. The preliminary choice is the MS1 series mechanical diaphragm metering pump of the Italian SEKO brand. The flow rate is 5.5-530 liters/hour, the maximum pressure is 10 bar, and its maximum Reynolds number can fully meet the requirements of fully turbulent flow.
②磨料和工件的选择 ②Selection of abrasive and workpiece
根据抛光加工装置实际需求,所需磨料的形状要比较规则,最好是直径为纳米级别的球形颗粒。 According to the actual needs of the polishing processing device, the shape of the required abrasive should be relatively regular, preferably spherical particles with a diameter of nanometers.
根据上述要求,本装置所选取的参考磨粒有以下两种: According to the above requirements, the reference abrasive grains selected by this device are as follows:
磨粒1:碳化硅(SiC)微粉,其基本特征参数如下:比重3.2,颜色:黑色或者绿色,目数:100000~1000。 Abrasive grain 1: silicon carbide (SiC) micropowder, its basic characteristic parameters are as follows: specific gravity 3.2, color: black or green, mesh number: 100,000-1,000.
磨粒2:氧化铝(Al2O3)微粉,其基本特征参数如下:比重3.95,颜色:白色,目数:100000~1000。 Abrasive grain 2: aluminum oxide (Al2O3) powder, its basic characteristic parameters are as follows: specific gravity 3.95, color: white, mesh number: 100000-1000.
本装置所选取的工件为:圆形单晶硅片或者圆形K9玻璃等平面或者曲率变换缓慢的大面积元器件。 The workpieces selected by this device are: circular monocrystalline silicon wafers or circular K9 glass and other flat or large-area components with slow curvature changes.
③抛光加工平台的设计 ③Design of polishing processing platform
为了解决设备在加工中生锈问题,抛光加工平台的机架、工件夹具安装底座采用喷塑处理工艺,不锈钢水槽、丝杠、丝杠螺母、直线导轨、连接螺钉都采用不锈钢材料,机架传动构件、圆盘形抛光工具、工件夹具采用铝制。 In order to solve the problem of equipment rusting during processing, the frame of the polishing processing platform and the mounting base of the workpiece fixture adopt the plastic spraying process. The stainless steel water tank, lead screw, lead screw nut, linear guide rail, and connecting screws are all made of stainless steel. Components, disc-shaped polishing tools, and workholding fixtures are made of aluminum.
对称安装在机架上的一对高精度丝杠传动系统,丝杠的有效传动行程为300毫米,平行布置在高精度丝杠传动系统两侧的高精度直线导轨的有效传动行程也为300毫米,所以圆盘形抛光工具安装在机架传动构件上的圆盘形抛光工具移动的行程为300毫米。工件夹具安装 在工件夹具安装底座上,置于不锈钢水槽内,工件夹具与圆盘形抛光工具同轴心安装,圆盘形抛光工具的底面与工件上表面间距不大于1毫米,由智能控制器精确控制实现。 A pair of high-precision screw transmission systems installed symmetrically on the frame, the effective transmission stroke of the screw is 300 mm, and the effective transmission stroke of the high-precision linear guide rails arranged in parallel on both sides of the high-precision screw transmission system is also 300 mm , so the disc-shaped polishing tool mounted on the frame transmission member moves a stroke of 300 mm. The workpiece fixture is installed on the workpiece fixture installation base and placed in a stainless steel water tank. The workpiece fixture and the disc-shaped polishing tool are installed concentrically. Precise control is achieved.
上述实施例只是本发明的较佳实施例,并不是对本发明技术方案的限制,只要是不经过创造性劳动即可在上述实施例的基础上实现的技术方案,均应视为落入本发明专利的权利保护范围内。 The above-described embodiments are only preferred embodiments of the present invention, and are not limitations to the technical solutions of the present invention. As long as they are technical solutions that can be realized on the basis of the above-mentioned embodiments without creative work, they should be regarded as falling into the scope of the patent of the present invention. within the scope of protection of rights.
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