CN105666327A - 利用滚轮修整复杂截面超硬磨料砂轮的方法、装置及机床 - Google Patents
利用滚轮修整复杂截面超硬磨料砂轮的方法、装置及机床 Download PDFInfo
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- CN105666327A CN105666327A CN201610120685.2A CN201610120685A CN105666327A CN 105666327 A CN105666327 A CN 105666327A CN 201610120685 A CN201610120685 A CN 201610120685A CN 105666327 A CN105666327 A CN 105666327A
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- 238000005296 abrasive Methods 0.000 title claims abstract description 107
- PNEYBMLMFCGWSK-UHFFFAOYSA-N al2o3 Chemical compound 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[O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 12
- 238000000034 method Methods 0.000 claims description 11
- 229910000831 Steel Inorganic materials 0.000 claims description 5
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 5
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- 229910001884 aluminium oxide Inorganic materials 0.000 claims description 4
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- 230000015572 biosynthetic process Effects 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N carbon Chemical compound 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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B53/00—Devices or means for dressing or conditioning abrasive surfaces
- B24B53/06—Devices or means for dressing or conditioning abrasive surfaces of profiled abrasive wheels
- B24B53/07—Devices or means for dressing or conditioning abrasive surfaces of profiled abrasive wheels by means of forming tools having a shape complementary to that to be produced, e.g. blocks, profile rolls
Abstract
本发明涉及一种利用滚轮修整复杂截面超硬磨料砂轮的方法、装置及机床，属于精密磨削技术领域。主要步骤为：A、将超硬磨料砂轮安装在机床主轴上；B、将滚轮修整机构安装在机床工作台上，该滚轮修整机构具有滚轮及驱动该滚轮转动的电机；C、通过超硬磨料砂轮与滚轮的相对位置移动，完成超硬磨料砂轮与滚轮的对刀，进而确定X轴、Y轴和Z轴的零点；D、启动机床及滚轮修整机构，令超硬磨料砂轮与滚轮转动；E、令超硬磨料砂轮与滚轮在三轴方向上作相对运动，并使二者进行磨削。本发明中，滚轮与被修整砂轮为点接触，修整力小。并使每次修整路线为等距平行轨迹，从原理上避免了由于滚轮磨损造成的修整精度降低。
Description
技术领域
[0001] 本发明涉及精密磨削技术领域，具体的说，是涉及一种利用滚轮修整复杂截面超 硬磨料砂轮的方法、装置及机床。
背景技术
[0002] 超硬磨料砂轮主要包括金刚石砂轮和CBN砂轮(立方氮化硼砂轮）。金刚石砂轮作 为超硬磨料砂轮，适于磨削硬、脆、有色金属和硬质合金、光学玻璃、陶瓷、宝石等高硬度、高 脆性的非金属材料。由于航空航天和电子等行业的迅速发展，使用金刚石砂轮等超硬磨料 砂轮磨削硬脆材料已经成为一项重要的技术，得到极大地重视。
[0003] CBN砂轮近年来在汽车等行业中黑色金属的高效精密磨削中大量使用。由于超硬 磨料砂轮的广泛使用，其修整技术已成为一个重要的技术领域。
[0004] 在汽车、电子和光学等行业中需要大量的圆柱面、球面、非球面等曲面加工，并且 对形状精度和表面质量的要求越来越高。因此，各种难加工材料的精密成形磨削（具有圆弧 截面的沟槽）、球面和非球面等曲面的精密磨削成为一项关键技术，而超硬磨料砂轮的曲线 截面轮廓精密修整方法是该技术的核心内容之一。
[0005]目前，通常采用两类方法对超硬磨料砂轮的曲线截面进行修整。
[0006] 第一类方法是采用固定形状的修整工具，如单点金刚石笔、碳化硅或不锈钢修整 块等。将修整工具固定在工作台上的，应用两轴联动系统和数控插补轨迹将超硬磨料砂轮 截面轮廓修整成为某种特定的曲线。
[0007] 第二类方法是采用与被修整砂轮截面形状相匹配的金刚石修整轮对砂轮截面轮 廓直接进行成形修整，将修整轮形状直接复写到砂轮轮廓上。
[0008] 采用以上第一类修整方法进行超硬磨料砂轮的修整时，修整力大，修整效率低，容 易在砂轮外圆周轮廓形成周期性振纹，导致磨削加工中在工件表面形成振纹。且修整工具 磨损快，影响修整砂轮的截面轮廓精度，不易实现高精度轮廓的修整。
[0009] 采用第二种修整方法，需要根据不用的砂轮截面形状定制不同的修整轮，修整轮 的制造复杂、成本高。修整过程中修整轮与砂轮为线接触，修整力大，适合用于普通磨料砂 轮的修整或陶瓷结合剂超硬磨料砂轮的修整，不适合大部分超硬磨料砂轮的修整。
[0010]因此，如何设计一种全新的装置与方法，来解决上述问题，是本领域技术人员所面 对的。
发明内容
[0011] 本发明的目的是为克服上述现有技术的不足，提供一种利用滚轮修整复杂截面超 硬磨料砂轮的方法。本发明通过滚轮与超硬磨料砂轮的相对螺旋运动，实现了对机床行程 范围内的任意半径的超硬磨料砂轮截面进行精密修整，无需根据砂轮截面形状特殊进行定 制金刚石修整滚轮或单独购置砂轮成形加工机床。
[0012] 为了达成上述目的，本发明采用如下技术方案：
[0013] -种利用滚轮修整复杂截面超硬磨料砂轮的方法，主要步骤如下：
[0014] A、将超硬磨料砂轮安装在机床主轴上；
[0015] B、将滚轮修整机构安装在机床工作台上，该滚轮修整机构具有滚轮及驱动该滚轮 转动的电机；
[0016] C、通过超硬磨料砂轮与滚轮的相对位置移动，完成超硬磨料砂轮与滚轮的对刀， 进而确定X轴、Y轴和Z轴的零点；
[0017] D、启动机床及滚轮修整机构，令超硬磨料砂轮与滚轮转动；
[0018] E、令超硬磨料砂轮与滚轮在三轴方向上作相对运动，并使二者进行磨削，完成复 杂截面的超硬磨料砂轮的修整。
[0019] 上述方法中，优选的是，所述步骤C中，按照Z轴、Y轴和X轴的先后顺序进行对刀。
[0020] 上述方法中，优选的是，Z轴的对刀流程为：
[0021] 测量出超硬磨料砂轮的厚度B与滚轮半径R1，再使超硬磨料砂轮侧面接触滚轮侧 面，记下刚接触时的Z轴坐标，减去(B+Ri/2)，即为Z轴的零点。
[0022] 上述方法中，优选的是，Y轴的对刀流程为：
[0023] 使超硬磨料砂轮与滚轮相对运动到Z轴零点位置，超硬磨料砂轮向Y轴负方向进 给，当超硬磨料砂轮最低点与滚轮最高点相接触时，即为Y轴零点。
[0024] 上述方法中，优选的是，X轴的对刀流程为：
[0025] 使超硬磨料砂轮与滚轮保持在ZY零点位置，超硬磨料砂轮向X轴负方向进给，当超 硬磨料砂轮最低点与滚轮X轴负方向端面最高点离开时，即为X方向零点。
[0026] 上述方法中，优选的是，所述滚轮修整机构包括基座，基座上安装有电机，电机通 联轴器和驱动轴带动滚轮转动。
[0027] 上述方法中，优选的是，所述滚轮为钼、钽、铌、不锈钢、碳化硅或氧化铝滚轮。
[0028]上述方法中，优选的是，所述机床为三轴联动机床或至少具有三个联动轴的机床。
[0029] -种实现利用滚轮修整复杂截面超硬磨料砂轮的方法的装置，该装置包括：
[0030] 底座；
[0031]所述底座上设有Y轴进给机构；
[0032] 所述Y轴进给机构带动X轴进给机构在Y方向运动；
[0033] 所述X轴进给机构带动Z轴进给机构在X方向运动；
[0034] 所述X轴进给机构上设有基座，基座上安装有电机，电机带动滚轮旋转；
[0035] 其中，所述滚轮在电机的带动下通过X轴、Y轴和Z轴三轴联动实现对超硬磨料砂轮 的修整。
[0036] 上述的装置中，任一轴的进给机构均包括一基板，基板上安装有电机，电机通过丝 杠副与滑轨副带动另一进给机构的基板沿自身丝杠副中丝杠的轴线方向运动。
[0037] -种机床，该机床上安装有上述的装置。
[0038]本发明的有益效果是：
[0039] (1)可以根据砂轮截面形状确定修整轨迹，完成具有圆形和非圆高次曲线截面形 状的超硬磨料砂轮的修整。
[0040] (2)滚轮与被修整砂轮为点接触，修整力小。增加了砂轮相对于滚轮轴向的运动， 滚轮磨损小，磨损均匀。
[0041] (3)调用宏程序来使每次修整路线为等距平行轨迹，从原理上消除因滚轮半径磨 损导致的砂轮修整后轮廓精度降低，进而完成复杂截面的超硬磨料砂轮的超精密修整。
[0042] (4)利用机床自身的操作系统实现修整的自动化，操作简便，对操作人员技术水平 要求低。
[0043] (5)砂轮的修形和修锐可一次完成。
[0044] (6)适于产品的对象或规格经常变化的精密机械加工或模具加工企业，适于单件 小批量生产，可大大缩短加工企业对新产品的响应时间，并极大地降低砂轮修整工具的购 置成本，具有广泛的市场推广前景。
附图说明
[0045] 图1为本发明中修整装置的结构图；
[0046] 图2为本发明中任一轴的进给机构的结构图；
[0047] 图3是图2中A-A向剖视图；
[0048] 图4为本发明中滚轮修整机构的结构图；
[0049] 图5为具体实施方式中修整圆弧截面超硬磨料砂轮空间螺旋曲线轨迹路线示意 图；
[0050] 图6为具体实施方式中修整圆弧截面超硬磨料砂轮YZ平面超硬磨料砂轮与滚轮相 对运动圆弧轨迹半径示意图；
[0051] 图7为具体实施方式中修整圆弧截面超硬磨料砂轮超硬磨料砂轮与滚轮Z轴方向 相对位置确定方法示意图；
[0052] 图8为具体实施方式中修整圆弧截面超硬磨料砂轮超硬磨料砂轮与滚轮Y轴方向 相对位置确定方法示意图；
[0053] 图9具体实施方式中修整圆弧截面超硬磨料砂轮为超硬磨料砂轮与滚轮X轴方向 相对位置确定方法示意图；
[0054]图10为试验例中修整后砂轮圆弧截面与理想轮廓分布示意图；
[0055] 图11为试验例中砂轮圆弧形轮廓形状偏差在砂轮轴向坐标上的分布示意图；
[0056] 图12为试验例中修整后的金刚石砂轮的圆周跳动误差图；
[0057]图13为具体实施方式中修整后的金刚石砂轮表面微观形貌图；
[0058] 其中：
[0059] 11、底座，12、X轴进给机构，13、Y轴进给机构，14、Z轴进给机构，15、滚轮修整机构， 16、PLC控制系统；
[0060] 21、电机，22、丝杠副，23、基板，24、滑轨副，25、联轴器，26、轴承支撑结构，27、PLC 控制线；
[0061 ] 31、基座，32、电机，33、联轴器，35和36均为轴承支撑结构，37冷却孔，38、PLC控制 线；
[0062] 41、超硬磨料砂轮，42、滚轮，43、螺旋插补空间轨迹路线；
[0063] 53、圆弧轨迹路线；
[0064]图10中：实线代表理想轮廓线，点代表实测轮廓点。
具体实施方式
[0065] 下面将结合附图对本发明进行详细说明。
[0066] 实施例1: 一种利用滚轮修整复杂截面超硬磨料砂轮的方法，本方法特别适用于圆 弧截面的超硬磨料砂轮，其主要步骤如下：
[0067] A、将超硬磨料砂轮41安装在能够三轴联动的机床主轴上；
[0068] B、将滚轮修整机构15安装在机床工作台上；
[0069] C、按照Z轴、Y轴和X轴的先后顺序，通过超硬磨料砂轮41与滚轮42的相对位置移 动，完成超硬磨料砂轮41与滚轮42的对刀，进而确定Z轴、Y轴和X轴的零点；
[0070] D、设定机床主轴和滚轮旋转速度，令超硬磨料砂轮41和滚轮42转动；
[0071] E、通过变曲率半径螺旋插补宏程序，令超硬磨料砂轮41相对于滚轮42进行三轴运 动，并使超硬磨料砂轮41相对于滚轮42进行磨削，完整超硬磨料砂轮41的修整。
[0072]参考图7所示，Z轴的对刀流程为:利用精密测量仪器(如千分尺)测量出超硬磨料 砂轮41的厚度B与滚轮42的半径R1，再使超硬磨料砂轮41的侧面接触滚轮42的侧面，记下刚 接触时的Z轴坐标，减去(B+Ri/2)，即为Z轴的零点。
[0073] 参考图8所示，Y轴的对刀流程为:使超硬磨料砂轮41与滚轮42相对运动到Z轴零点 位置，超硬磨料砂轮41向Y轴负方向进给，当超硬磨料砂轮41最低点与滚轮42最高点相接触 时，即为Y轴零点。
[0074]参考图9所示，X轴的对刀流程为:使超硬磨料砂轮41与滚轮42保持在ZY零点位置， 超硬磨料砂轮41向X轴负方向进给，当超硬磨料砂轮41最低点与滚轮X轴负方向端面最高点 离开时，即为X方向零点。
[0075]参考图4所示，在本实施例中，所述滚轮修整机构15包括基座31，基座31上安装有 电机32,电机32通联轴器33和驱动轴带动滚轮42转动。该驱动轴通过轴承支撑结构35和轴 承支撑结构36安装在基座31上。同时，滚轮修整机构15上具有冷却孔37，可以使微量冷却润 滑油通过高压气体经冷却孔37为高速旋转的驱动轴进行冷却。
[0076]电机32根据不同的需要，可以选择为步进电机或伺服电机，其通过PLC控制线38与 控制系统相连接，实现正反转。
[0077]其中，所述滚轮42可为钼、钽、铌、不锈钢、碳化硅或氧化铝滚轮。
[0078]参考图5所示，超硬磨料砂轮41与滚轮42在X轴、Y轴和Z轴的联动相对运动轨迹为 螺旋插补空间轨迹路线43。
[0079] 从分解螺旋运动轨迹的角度考虑，参考图6所示，YZ平面内超硬磨料砂轮41与滚轮 42相对运动轨迹为圆弧轨迹路线53。插补半径R为超硬磨料砂轮41曲线截面半径R与滚轮42 半径R 1之和。通过调用宏程序，使滚轮42因磨耗半径不断减小时，超硬磨料砂轮41截面与滚 轮42干涉圆弧的曲率半径保持超硬磨料砂轮41截面圆弧半径R不变。
[0080] X方向上来说，超硬磨料砂轮41与滚轮42的相对运动轨迹为直线。
[0081] 作为另一种情况，还可根据待修复砂轮的曲面形状，采用离线编程方法，确定待修 复砂轮的非圆曲线截面形状，采用XYZ三轴联动的运动轨迹对加工区域内具有任意高次曲 线的截面的超硬磨料砂轮进行修形和修锐。
[0082]采用了上述方法后，本发明利用滚轮点接触数控插补修整法从修整原理上克服砂 轮半径磨损导致的误差。且需求的修整系统的结构简单，修整的精度高，效率高，稳定性好、 工具寿命长，整个修整可以使用自动化控制，对操作工人的技术水平要求较低。
[0083]实施例2: -种利用滚轮修整复杂截面超硬磨料砂轮的方法，该方法基于图1-3所 示的装置及图4所示的滚轮修整机构15来实现。在修整前，需要将三轴联动装置和滚轮修整 机构均安装于不能实现三轴联动的机床上，并通过PLC控制系统16控制三轴联动装置上安 装的滚轮修整机构15的运动轨迹。
[0084]参考图1-3所示，该三轴联动装置包括底座11;所述底座11上自下至上依次安装有 Y轴进给机构13、X轴进给机构12和Z轴进给机构14。所述Y轴进给机构13带动X轴进给机构12 在Y轴方向运动;X轴进给机构12带动Z轴进给机构14在X轴方向运动;Z轴进给机构14上安装 有滚轮修整机构15并带动滚轮修整机构15在Z轴方向运动。
[0085]上述的三轴联动装置中，任一轴的进给机构均包括一基板23,基板23上安装有电 机21，电机21通过联轴器25将动力传递给丝杠副22。该进给机构通过丝杠副22与滑轨副24 带动另一进给机构的基板23沿自身丝杠副中丝杠的轴线方向进行运动。
[0086] 每个进给机构中，丝杠副22的丝杠由轴承支撑机构26支撑，电机21通过PLC控制线 27与控制系统相连接，接收指令。
[0087] 参考图4所示，所述滚轮修整机构15包括基座31，基座31上安装有电机32,电机32 通联轴器33和驱动轴带动滚轮42转动。该驱动轴通过轴承支撑结构35和轴承支撑结构36安 装在基座31上。同时，滚轮修整机构15上具有冷却孔37,可以使微量冷却润滑油通过高压气 体经冷却孔37为高速旋转的驱动轴进行冷却。
[0088] 电机32和电机21根据不同的需要，可以选择为步进电机或伺服电机，电机32通过 PLC控制线38与控制系统相连接，实现指令正反转。
[0089]其中，所述滚轮42可为钼、钽、铌、不锈钢、碳化硅或氧化铝滚轮。
[0090] 在本实施例中，进行修整的方法如下：
[0091] A、将图1-3所示的三轴联动机构安装在机床的工作台上；
[0092] B、将超硬磨料砂轮41安装在机床的旋转轴上；
[0093] C、按照Z轴、Y轴和X轴的先后顺序，通过滚轮42与超硬磨料砂轮41的相对位置移 动，完成超硬磨料砂轮41与滚轮42的对刀，进而确定Z轴、Y轴和X轴的零点；
[0094] D、设定机床旋转轴和滚轮旋转速度；，令超硬磨料砂轮41和滚轮42转动；
[0095] E、采用基于宏程序的等距平行空间螺旋轨迹或直接采用螺旋线插补指令，令滚轮 42相对于超硬磨料砂轮41进行三轴运动，并使超硬磨料砂轮41相对于滚轮42进行磨削，完 整超硬磨料砂轮41的修整。
[0096]本实施例中，进行三轴运动的物体为滚轮42,仅进行转动的物体为超硬磨料砂轮 41，因此在相对运动关系上与实施例1正好相反。即：利用滚轮42的螺旋线运动轨迹，同样能 实现对超硬磨料砂轮41的修整。
[0097]实施例3: -种机床，该机床无法完成三轴联动运动。但是在该机床上安装有图1-3 所示的三轴联动修整装置及图4所示的滚轮修整机构15,进而实现了利用该机床进行超硬 磨料砂轮的修复。
[0098]试验例:采用CNC三轴联动超精密成形磨床，利用粒度为180#的GC滚轮（即修整轮） 对粒度为120#的金刚石砂轮进行修整。滚轮初始外径25mm，长度20mm。金刚石砂轮外径 200mm，厚度16mm，截面为半径为25mm的圆弧。修整参数如表1所示。采用如图4所示砂轮修整 机构15，利用如图5图6所示的插补路线和图7、图8、图9所示的相对位置确定方法，对金刚石 砂轮进行修整。得到结果如图10所示的砂轮截面圆弧轮廓、如图11所示的砂轮截面圆弧与 理想圆弧的误差分布和如图12所示的外圆跳动误差分布。
[0099]修整后的金刚石砂轮表面微观形貌图，如图13所示。
[0100]由测量结果可以看出，修整后的金刚石砂轮圆弧轮廓形状精度达到〇.7μπι/πιπι;圆 周跳动误差7μπι;砂轮表面的微观形貌说明修整后磨粒很好地突出在砂轮表面。因此，修形 精度和修锐情况两方面都获得了很好的修整效果，明显优于现在普遍使用的成型滚轮修整 以及磨石修整等砂轮修整方法。
[0101]表1石英玻璃磨削参数
[0103]对所公开的实施例的上述说明，使本领域专业技术人员能够实现或使用本发明。 对实施例的多种修改对本领域的专业技术人员来说将是显而易见的，本文中所定义的一般 原理可以在不脱离本发明的精神或范围的情况下，在其它实施例中实现，未予以详细说明 的部分，为现有技术，在此不进行赘述。因此，本发明将不会被限制于本文所示的这些实施 例，而是要符合与本文所公开的原理和特点相一致的最宽的范围。
Claims (10)
1. 一种利用滚轮修整复杂截面超硬磨料砂轮的方法，其特征在于，步骤如下： A、 将超硬磨料砂轮安装在机床主轴上； B、 将滚轮修整机构安装在机床工作台上，该滚轮修整机构具有滚轮及驱动该滚轮转动 的电机； C、 通过超硬磨料砂轮与滚轮的相对位置移动，完成超硬磨料砂轮与滚轮的对刀，进而 确定X轴、Y轴和Z轴的零点； D、 启动机床及滚轮修整机构，令超硬磨料砂轮与滚轮转动； E、 令超硬磨料砂轮与滚轮在三轴方向上作相对运动，并使二者进行磨削，完成复杂截 面的超硬磨料砂轮的修整。
2. 根据权利要求1所述的方法，其特征在于，所述步骤C中，按照Z轴、Y轴和X轴的先后顺 序进行对刀。
3. 根据权利要求2所述的方法，其特征在于，Z轴的对刀流程为： 测量出超硬磨料砂轮的厚度B与滚轮半径Ri，再使超硬磨料砂轮侧面接触滚轮侧面，记 下刚接触时的Z轴坐标，减去(B+Ri/2)，即为Z轴的零点。
4. 根据权利要求2所述的方法，其特征在于，Y轴的对刀流程为： 使超硬磨料砂轮与滚轮相对运动到Z轴零点位置，超硬磨料砂轮向Y轴负方向进给，当 超硬磨料砂轮最低点与滚轮最高点相接触时，即为Y轴零点。
5. 根据权利要求2所述的方法，其特征在于，X轴的对刀流程为： 使超硬磨料砂轮与滚轮保持在ZY零点位置，超硬磨料砂轮向X轴负方向进给，当超硬磨 料砂轮最低点与滚轮X轴负方向端面最高点离开时，即为X方向零点。
6. 根据权利要求1所述的方法，其特征在于，所述滚轮修整机构包括基座，基座上安装 有电机，电机通联轴器和驱动轴带动滚轮转动。
7. 根据权利要求1所述的方法，其特征在于，所述滚轮为钼、钽、铌、不锈钢、碳化硅或氧 化铝滚轮。
8. 根据权利要求1所述的方法，其特征在于，所述机床为三轴联动机床或至少具有三个 联动轴的机床。
9. 一种实现利用滚轮修整复杂截面超硬磨料砂轮的方法的装置，其特征在于，该装置 包括： 底座； 所述底座上设有Y轴进给机构； 所述Y轴进给机构带动X轴进给机构在Y方向运动； 所述X轴进给机构带动Z轴进给机构在X方向运动； 所述X轴进给机构上设有基座，基座上安装有电机，电机带动滚轮旋转； 其中，所述滚轮在电机的带动下通过X轴、Y轴和Z轴三轴联动实现对超硬磨料砂轮的修 整。
10. -种机床，其特征在于，该机床上安装有权利要求9所述的利用滚轮修整复杂截面 超硬磨料砂轮的方法的装置。
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