CN112139863B - Valve core edge grinding burr form prediction method based on energy conservation - Google Patents

Valve core edge grinding burr form prediction method based on energy conservation Download PDF

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CN112139863B
CN112139863B CN202011058566.1A CN202011058566A CN112139863B CN 112139863 B CN112139863 B CN 112139863B CN 202011058566 A CN202011058566 A CN 202011058566A CN 112139863 B CN112139863 B CN 112139863B
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grinding
burr
cutting
deformation
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陈明
安庆龙
蔡晓江
明伟伟
陶正瑞
周如好
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Shanghai Jiaotong University
Shanghai Aerospace Control Technology Institute
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Shanghai Aerospace Control Technology Institute
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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
    • B24B1/00—Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes
    • 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
    • B24B9/00—Machines or devices designed for grinding edges or bevels on work or for removing burrs; Accessories therefor
    • B24B9/02—Machines or devices designed for grinding edges or bevels on work or for removing burrs; Accessories therefor characterised by a special design with respect to properties of materials specific to articles to be ground

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  • Mechanical Engineering (AREA)
  • Grinding And Polishing Of Tertiary Curved Surfaces And Surfaces With Complex Shapes (AREA)

Abstract

A valve core edge grinding burr form prediction method based on energy conservation is characterized in that a valve core working edge grinding micro burr form prediction model is built according to a friction-plowing-cutting removal mechanism of materials in a grinding process, a fourth deformation area theory and a chip bending model based on an energy conservation law, and grinding process optimization is achieved according to the action relation of grinding depth, feeding speed and grinding wheel speed on burr forms. The invention establishes an energy conservation-based edge grinding micro burr form prediction model, provides basis for active control and accurate removal of burr formation, and can remarkably reduce or inhibit burr formation.

Description

Valve core edge grinding burr form prediction method based on energy conservation
Technical Field
The invention relates to the technology in the field of machining, in particular to a valve core edge grinding burr form prediction method based on energy conservation.
Background
The edge of the valve core of the servo valve is the edge of the intersection of the end surface of each step of the valve core and the outer circular surface. The requirement for these edges is that they not be blunted, that sharp edges be maintained and that no burrs be left. The geometric shape of the edge of the valve core and the axial size precision determine the performance of the servo valve, and are key factors for ensuring that the servo valve can be in a correct position in the oil inlet and outlet processes. The lapping amount of the valve core and the valve sleeve is taken as the key characteristic of the servo valve, and the matching size, namely the control of the lapping amount has direct relation to the performance of the servo valve and the matching with a servo mechanism. The lap joint quantity is too small, so that the static consumption of the servo valve can be increased, and the self-excitation possibility of the servo valve can be increased; too much overlap can affect performance near the zero position of the servo valve. The valve core is used as an important component of a matching part, and the processing quality of the working edge of the valve core directly influences the size of the lap joint quantity and the working performance of the servo valve. When burrs exist on the working edge, the flexibility of the matching movement of the servo valve control pair part and the important performance of the superposition amount can be directly influenced.
At present, the last end face grinding process of a valve core of a servo valve is mainly carried out on a precise cylindrical grinding machine, a grinding wheel is manually trimmed at first, then the valve core is fixed on the front tip and the rear tip of the cylindrical grinding machine, the grinding wheel leans against a working edge to horizontally move through a guide rail, the working edge is ground, the horizontal feeding amount is controlled, and the lap joint size is ensured, so that the size meets the requirement. The method for removing the micro burrs (including the plastic deformation micro flanging generated in the material processing) generated in the current working edge processing comprises the following steps: moving the valve core to a deburring device, repeatedly extruding the valve core along the excircle and the end face respectively by using a ground hard alloy strip and a razor blade coated with metallographic abrasive paper, and possibly causing defects on the working edge by manual deburring; in addition, because allowance control and measurement cannot be accurately carried out in the end face grinding process, the off-position grinding matching process needs to be carried out for multiple times, the machining precision cannot be well guaranteed, the integrity of the working edge is extremely easy to damage, the working efficiency is low, and the rejection rate is extremely high.
Disclosure of Invention
Aiming at the problems that in the prior art, due to the complexity of the grinding process, the size of grinding burrs is too small, and the reliability of parameters obtained by detection in the grinding process is poor; and the detection procedure of the tiny burr form of the edge grinding of the servo valve spool is complicated, and the like, and the method for predicting the burr form of the edge grinding of the spool based on energy conservation is provided, and based on the deep analysis of the forming mechanism of burrs, the formation of the burrs is obviously reduced or inhibited by establishing a mathematical model and optimizing grinding parameters.
The invention is realized by the following technical scheme:
the invention relates to a valve core edge grinding burr form prediction method based on energy conservation.
The friction-plowing-cutting removal mechanism of the material in the grinding process is as follows: the contact process of the abrasive particle cutting edge and the metal material comprises the following steps: a skiving phase, a plowing phase and a cutting phase.
In the sliding and rubbing stage, the cutting depth of the abrasive particles is small, and the surface of the workpiece only generates elastic deformation of the material.
In the plowing stage, as the depth of the abrasive particles cutting into the workpiece is increased, the pressure between the abrasive particles and the surface of the workpiece is gradually increased, so that the abrasive particles plow grooves on the surface of the workpiece, and bulges formed by plastic flow of materials appear on two sides of the grooves.
In the cutting stage, when the abrasive particles continue to cut into the surface of the workpiece to a critical value, part of the material is subjected to shear slip, and chips are formed and flow out of the front face of the abrasive particles.
The fourth deformation zone theoretical model is as follows: in a stable cutting process, the cutting zone generally comprises: three deformation zones, which are respectively a first deformation zone (zone I), a second deformation zone (zone II), a third deformation zone (zone III), wherein: the I area is a main cutting area and generates shearing, sliding and deformation of a workpiece material; zone II produces the main area of frictional deformation between the tool and the chip; friction between the tool and the machined surface occurs primarily in zone III. A fourth deformation zone (zone IV), i.e. the negative shear zone, is also present during the formation of the burr.
The chip bending model is as follows: the bending of the chip is the most fundamental reason for the influence of the thermal coupling effect of the grinding force on the chip. The abrasive particles bring stress strain to the chips in a second deformation area of cutting, the chips have certain thickness, the chips close to the cutting area and far away from the cutting area have different force and heat effects, the stress strain of the part close to the cutting area is larger, the part far away from the cutting area is smaller, and therefore the chips are cutIs curved. The chip radius can be obtained through tests, but because the size of the grinding chip is too small, the grinding chip cannot be directly observed and measured, and the observation difficulty of manufacturing a metallographic specimen is large, the theoretical calculation formula of the average bending radius of the chip is given by the invention:
Figure GDA0003302941220000021
Figure GDA0003302941220000022
wherein: ω is a chip bending rotation angular velocity, which is a function related to the grinding speed V, i.e., ω ═ h (V); rho is the variation of the slip linear velocity, and rho is the grinding speed V and the grinding depth agA function relating abrasive grain size d and chip shear strain γ, i.e., ρ ═ j (V, a)g，d，γ)。
The energy conservation refers to: energy W required for burr formationburrEnergy W for generating shear deformation in materialshearAnd energy W for bending deformation of materialbeadingAnd (4) summing. Specifically, when the abrasive particle cutting process reaches a critical point where no chips are generated, normal cutting is finished, edge burrs begin to be formed, and all the originally generated chips are used for generating the burrs.
The valve core working edge grinding micro burr form prediction model is as follows: the height and width of the burr, the material, the physical properties of the grinding wheel, the grain size d of the abrasive grain, and the grinding depth agGrinding speed V and workpiece feed speed VfThe mapping relationship between them.
The action relation of the grinding depth, the feeding speed and the grinding wheel speed to the burr form is as follows: the abrasive particles have larger cutting edge radius and effective negative rake angle, the size effect is obvious, so the formation of grinding outlet burrs is more complicated, and the factors of the size effect, the negative rake angle and the cutting edge radius need to be considered in a burr form prediction analysis model.
The burr form prediction analysis model is suitable for but not limited to grinding outlet burrs into turning burrs.
Drawings
FIG. 1 is a schematic view of a fourth deformation zone of the present invention;
fig. 2 is a schematic diagram of an edge outlet burr formation process.
Detailed Description
As shown in fig. 1 and 2, the method for predicting the form of the grinding burr of the edge of the valve element based on energy conservation according to the present embodiment includes the following specific steps:
step one, as shown in fig. 1, when the grinding process reaches the edge of the workpiece, due to the fact that the rigidity of the material at the edge of the workpiece is reduced, elastic deformation and plastic deformation are gradually generated under the action of a cutter, the rigidity of the material at the edge of the workpiece is reduced, the elastic deformation and the plastic deformation are gradually generated under the action of abrasive particles, the material at the edge of the valve core is gradually deformed towards the grinding feeding direction, and after the grinding process is finished, burrs shown in fig. 1 are finally formed. Grinding the outlet burr height comprises: height of burr root, i.e. burr height h1And chip bending height h2Then the overall height h of the outlet burreComprises the following steps: h ise＝h1+h2As shown in fig. 2.
According to the geometric constraint in fig. 2, the following results are obtained:
Figure GDA0003302941220000031
wherein: dx is a differential unit of relative displacement of the abrasive particles and the workpiece, psi is a rotation angle of the end face material, alpha0Is the initial negative shearing angle, d alpha is the shearing angle variation, V is the relative cutting speed of the abrasive particles and the workpiece, beta is the workpiece edge end face angle, eta is the included angle between the shearing line and the surface to be machined of the workpiece, and the burr thickness w is l' sin alpha t tan alpha0Height h of burr1＝(ag+w)sinψ＝(ag+t tanα0)sin(β-α0) When is coming into contact with
Figure GDA0003302941220000032
When h is present1＝(ag+ttanα0)cosα0。
Step two, when the critical point of no chip generation is reached in the abrasive particle cutting process, the normal cutting is finished at the moment, the outlet burr begins to be formed, and the original chip generation work is all used for generating the burr from the moment, namely the burr is generatedWchip＝WburrWherein: energy W required for burr formationburrEnergy W for generating shear deformation in materialshearAnd energy W of bending deformation of materialbendingSum, i.e. Wburr＝Wshear+Wbending。
Since the stress in each region is uniformly distributed in the negative shear plane, the burr generates the required shear deformation energy
Figure GDA0003302941220000033
Wherein: tau isyDenotes the shear yield strength of the material, gamma denotes the shear strain, V*Representing the volume of the material.
Energy required for plastic bending deformation of material per unit cut width
Figure GDA0003302941220000034
Figure GDA0003302941220000035
Wherein: sigmayIndicating the yield strength of the material.
Obtaining the energy required by burr formation according to the above calculation formula
Figure GDA0003302941220000036
Step three, grinding force per unit area
Figure GDA0003302941220000037
Wherein: sigma*The unit grinding force constant and the epsilon index constant can be obtained by grinding test, and the average cutting area of single abrasive grain
Figure GDA0003302941220000038
Wherein: vwIs the linear velocity of the workpiece, VsThe linear velocity of the grinding wheel is the linear velocity,
Figure GDA0003302941220000041
average distance of grinding wheel grains, /)sThe contact length of the grinding wheel and the workpiece.
For cylindrical grinding, the contact length of the grinding wheel and the workpiece
Figure GDA0003302941220000042
Wherein: dwIs the diameter of the workpiece, dsIs the diameter of the grinding wheel.
The work of generating chips is obtained through the cutting force and the action distance of the cutting force
Figure GDA0003302941220000043
Wherein: fgAnd t is the distance from the abrasive particle cutting edge to the end face of the workpiece, and is the grinding resistance in the feeding direction. The work of generating chips is obtained from the expression of grinding force per unit area
Figure GDA0003302941220000044
Obtaining the distance from the abrasive particle cutting edge to the end face of the workpiece based on energy conservation
Figure GDA0003302941220000045
Further obtain
Figure GDA0003302941220000046
Preferably, the initial negative shear angle α0Typically 20 to 60, and can be experimentally derived, the primary factor in size is related to workpiece edge stiffness, such as the face angle and whether the workpiece edge is supported.
And step four, in the burr forming process, the removed material is continuously pushed to the burr forming direction to drive the formed burrs to be further away from the workpiece. The cutting speed of the grinding process is high, the friction force and the generated heat are very large, and the speed of separating materials from a workpiece is higher. Thus, the burr leading end bent portion is formed, and the height thereof is defined as the chip bent height h in the present embodiment2Because its value can be approximated to the average grinding chip radius Rc. When the grinding depth is small and the critical chip thickness is not reached, the bending burr height is approximately 0 by default.
The chip has high bendingDegree of rotation
Figure GDA0003302941220000047
Namely, a valve core working edge grinding micro burr form prediction model, wherein: ω is a chip bending rotation angular velocity expressed as a function related to the grinding speed V, i.e., ω ═ h (V); rho is the variation of the slip linear velocity, and rho is the grinding speed V and the grinding depth agA function relating abrasive grain size d and chip shear strain γ, i.e., ρ ═ j (V, a)g，d，γ)。
Analytically, the bending radius R of the grinding chipcParameters having influence, in addition to the material, the properties of the grinding wheel itself, mainly with the grinding speed V, the grinding depth agThe abrasive grain size d. According to the metal cutting principle, the chip bending radius increases as the chip deformation coefficient decreases. As the grinding speed V increases, the chip bending radius increases. The reason for this is that during metal cutting, the plastic deformation is slower than the propagation speed of the elastic deformation, and as the grinding speed increases, the metal flow speed is gradually greater than the plastic deformation speed, which causes the first deformation zone to move backwards, which in turn reduces the chip deformation coefficient and increases the chip bending radius. In addition, during the increase in grinding speed, the tool-chip friction coefficient decreases, which also leads to a decrease in the coefficient of deformation and an increase in the chip bending radius. When the granularity d of the grinding wheel is reduced, the effective negative rake angle of the abrasive particles is increased, the radius of the cutting edge is also increased, the deformation coefficient of the cutting chip is reduced, and the bending radius of the cutting chip is increased. And the grinding depth agThe larger the thickness of the chip, the better the chip rigidity, the smaller the deformation coefficient, and the larger the chip bending radius.
In summary, the height and width of the burr are all obtained, and it can be seen that, except for the physical characteristics of the material and the grinding wheel, the grinding depth has the greatest influence on the size of the burr, and the grinding speed and the grinding wheel granularity also have influence on the size of the burr.
Through specific practical experiments, the laser confocal sensor is used for realizing online detection and evaluation of the contour of the working edge of the valve element, three-dimensional reconstruction of the shape of the burr of the working edge is realized through Matlab data processing, the same experiment parameters are substituted into the model, and the burr height error is within 1 percent and the burr width error is about 1.2 percent.
Compared with the prior art, the method firstly discloses a valve core working edge grinding burr forming mechanism based on a friction-plowing-cutting removing mechanism and a fourth deformation area theory, establishes an edge grinding micro burr form prediction model based on energy conservation, and provides a basis for active control and accurate removal of burr formation.
The foregoing embodiments may be modified in many different ways by those skilled in the art without departing from the spirit and scope of the invention, which is defined by the appended claims and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

Claims (4)

1. A valve core edge grinding burr form prediction method based on energy conservation is characterized in that a valve core working edge grinding micro burr form prediction model is established based on an energy conservation law according to a friction-plowing-cutting removal mechanism, a fourth deformation area theory and a chip bending model of materials in a grinding process, and grinding process optimization is realized according to the action relation of grinding depth, feeding speed and grinding wheel speed on the burr form;
the valve core working edge grinding micro burr form prediction model is as follows: the height and width of the burr, the material, the physical properties of the grinding wheel, the grain size d of the abrasive grain, and the grinding depth agGrinding speed V and workpiece feed speed VfThe mapping relationship between the two;
the valve core working edge grinding micro burr form prediction model is the bending height of the cutting chip
Figure FDA0003406500180000011
Wherein: ω is a chip bending rotation angular velocity expressed as a function related to the grinding speed V, i.e., ω ═ h (V); variation ρ ═ j (V, a) of slip linear velocitygD, γ), i.e. ρ is the grinding speed V and the grinding depth agAbrasive grain size d, chip shear strain gamma phaseA function of closing, wherein eta is an included angle between the shearing line and the surface to be processed of the workpiece;
the energy conservation refers to: energy W required for burr formationburrEnergy W for producing shear deformation of materialshearAnd energy W for bending deformation of materialbeadingIn particular, when the abrasive particle cutting process reaches a critical point where no chips are generated, and normal cutting is finished, edge burrs begin to be formed, and all the originally generated chips are used for generating the burrs.
2. The valve core edge grinding burr form prediction method based on energy conservation as claimed in claim 1, wherein the friction-plowing-cutting removal mechanism of material during grinding is: the contact process of the abrasive particle cutting edge and the metal material comprises the following steps: a sliding friction stage, a plowing stage and a cutting stage;
in the sliding and rubbing stage, the cutting depth of the abrasive particles is small, and the surface of the workpiece only generates elastic deformation of the material;
in the plowing stage, along with the increase of the depth of the abrasive particles cutting into the workpiece, the pressure between the abrasive particles and the surface of the workpiece is gradually increased, so that the abrasive particles plow groove marks on the surface of the workpiece, and bulges formed by plastic flow of materials appear on two sides of the groove marks;
in the cutting stage, when the abrasive particles continue to cut into the surface of the workpiece to a critical value, part of the material is subjected to shear slip, and chips are formed and flow out of the front face of the abrasive particles.
3. The valve core edge grinding burr form prediction method based on energy conservation as claimed in claim 1, wherein said fourth deformation region theoretical model is: in a stable cutting process, the cutting zone comprises: three deformation zones, which are respectively a first deformation zone (zone I), a second deformation zone (zone II), a third deformation zone (zone III), wherein: the I area is a main cutting area and generates shearing, sliding and deformation of a workpiece material; zone II produces the main area of frictional deformation between the tool and the chip; the friction between the tool and the machined surface occurs mainly in zone III and a fourth deformation zone (zone IV), i.e. the negative shear zone, is also present during the formation of the burr.
4. The method for predicting the grinding burr form of the edge of the valve element based on the energy conservation as claimed in claim 1, wherein the action relationship of the grinding depth, the feed speed and the grinding wheel speed on the burr form is as follows: the abrasive particles have larger cutting edge radius and a negative front angle, and the size effect is obvious, so the formation of burrs at a grinding outlet is more complicated, and the factors of the size effect, the negative front angle and the cutting edge radius need to be considered in a burr form prediction analysis model.
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CN108648153A (en) * 2018-04-25 2018-10-12 大连理工大学 Honeycomb core surface shape measurement data burr minimizing technology
CN108733912A (en) * 2018-05-17 2018-11-02 南京理工大学 A kind of robot rotary ultrasonic drilling CFRP/ aluminium alloy laminated construction outlet burr height prediction technique
CN110549188A (en) * 2019-08-28 2019-12-10 上海交通大学 Valve core synchronous grinding and deburring integrated method and system based on superposition amount detection

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CN108648153A (en) * 2018-04-25 2018-10-12 大连理工大学 Honeycomb core surface shape measurement data burr minimizing technology
CN108733912A (en) * 2018-05-17 2018-11-02 南京理工大学 A kind of robot rotary ultrasonic drilling CFRP/ aluminium alloy laminated construction outlet burr height prediction technique
CN110549188A (en) * 2019-08-28 2019-12-10 上海交通大学 Valve core synchronous grinding and deburring integrated method and system based on superposition amount detection

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