CN1785566A - Electric spark-mechanical compound shaping method of metal bindnig agent extra hard abradant sand wheel - Google Patents
Electric spark-mechanical compound shaping method of metal bindnig agent extra hard abradant sand wheel Download PDFInfo
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- CN1785566A CN1785566A CN 200510032590 CN200510032590A CN1785566A CN 1785566 A CN1785566 A CN 1785566A CN 200510032590 CN200510032590 CN 200510032590 CN 200510032590 A CN200510032590 A CN 200510032590A CN 1785566 A CN1785566 A CN 1785566A
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Abstract
An electrospark-mechanical method for shaping the abrasive disc made of metallic binder and superhard abrasive material includes such steps as electrospark shaping until the electrospark can not be generated, mechanical shaping by brake-type silicon carbide roller for removing all projected abrasive particles, alternatively repeating said steps for 2 hr, lowering the electric parameters, and sequentially repeating said steps until its shaping accuracy reaches 6 microns.
Description
Technical field
The present invention relates to the shaping methods of metal bindnig agent extra hard abradant sand wheel, further be meant its electric spark-mechanical compound shaping method.
Background technology
Along with increasingly extensive application of hard brittle material such as carbide alloy, engineering ceramics, optical glass, hardened steel and semiconductors, it is efficient, precision processing technology has become one of current research focus, and grinding is also increasingly important in whole field of machining as the most effective manufacturing process of this type of material.
But because this type of material has high strength, high rigidity and high fragility, grinding force is big in its grinding process, grinding temperature is high, grinding efficiency is low, and very easily causes the emery wheel passivation, and this has brought huge challenge for traditional grinding process.The application of super-abrasive grinding wheel solves these problems basically, still it is repaired but to have suitable challenge, also is one of emphasis that comes in the past few decades grinding research.Super-abrasive grinding wheel commonly used generally is shaped with resin, pottery, metallic bond and electro-plating method.Metal bindnig agent extra hard abradant sand wheel than the hardness height of resin and vitrified bond, intensity is big, the conformal ability is strong, wearability good.But the self-sharpening of metal bindnig agent extra hard abradant sand wheel is poor, stop up easily, easily produce the exciting force that is caused by emery wheel off-centre in grinding, thereby influences the stability and the grinding surface quality of grinding process; For this reason, need regularly emery wheel to be carried out shaping.Yet the hard bond of metal bindnig agent extra hard abradant sand wheel has brought great difficulty for the shaping of emery wheel, has finishing time length, repairs characteristics such as difficulty is big, dressing efficiency is low.Therefore, efficient, the high-quality dressing technique of metal bindnig agent extra hard abradant sand wheel become the key technology that realizes hard brittle material precision and ultraprecise processing, high-speed and high-efficiency grinding, plunge grinding and grinding automation.
At present, there is lot of documents that the finishing of metal bindnig agent extra hard abradant sand wheel is reported, as adopting laser shaping, electrochemistry shaping, electric discharge dressing etc.All more or less there is certain problem in these shaping methods.Be still waiting research as the adaptive control technology of laser shaping, laser reconditioning mechanism is imperfection etc. also; Electrochemistry shaping method is owing to the influence of the electric field between tool-electrode and the emery wheel, flow field, electrode reaction dynamic process, and machining gap does not wait, thereby the concave-convex surface that is trimmed is inhomogeneous; The electric discharge dressing method has advantages such as plastic precision height, apparatus structure be simple, and this is used widely it in the shaping of metal bindnig agent extra hard abradant sand wheel.But the electric discharge dressing in the past reporting is mainly at the fine particle size emery wheel, and seedy degree emery wheel not, this be since during electric discharge dressing negative and positive two clearance between poles need keep within the specific limits, when emery wheel abrasive particle diameter is big, may cause the gap at negative and positive the two poles of the earth to exceed this scope.
Summary of the invention
The technical problem to be solved in the present invention is, defective at the prior art existence, a kind of electric spark-mechanical compound shaping method of metal bindnig agent extra hard abradant sand wheel is proposed, it removes the metallic bond of emery wheel by electric spark, thereby reduce the intensity of controlling of emery wheel abrasive particle, the abrasive particle that worn mechanically again eccentric part is outstanding and is finally reached the shaping purpose so that electric discharge dressing proceeds.
Technical solution of the present invention is that the electric spark-mechanical compound shaping method of described metal bindnig agent extra hard abradant sand wheel is:
At first emery wheel is carried out electric discharge dressing, can't generate until electric spark;
Adopt brake type carborundum roller to carry out mechanical shaping then, to outstanding abrasive particle is worn, promptly height of protrusion is zero;
Above-mentioned electric discharge dressing and mechanical shaping process were gone round and begun again after a period of time, reduced the electrical guiding rule parameter;
Repeat described electric discharge dressing and mechanical shaping process more in regular turn, till making emery wheel reach required plastic precision.
Below the present invention made further specify.
In electric discharge dressing, pole clearance g is the minimum clearance of negative and positive two interpolars; Discharging gap g
dBe meant the metallic bond of wheel face in the time of producing spark discharge and the ultimate range between the tool-electrode, this gap is a constant when electrode material and electrical guiding rule parameter constant.The necessary condition that electric spark produces can be expressed from the next:
g＜g
d ①
For the shaping of coarseness emery wheel, need to be divided into two stages according to the relation of pole clearance and discharging gap:
(1) when satisfying formula 1. the time, promptly as Fig. 1. during situation (a), utilize electric spark to carry out shaping.Galvano-cautery phenomenon when the electric discharge dressing process is based on high-frequency impulse spark discharge between tool-electrode and the metal bonded wheel is come the metallic bond of ablation wheel face, thereby eliminates the off-centre of emery wheel and reach the purpose of shaping.Electric discharge dressing can adopt as Fig. 1. (b) shown device, it with the high frequency direct current pulse power source as power supply, tool-electrode is linked to each other with the negative pole of power supply, and as the discharge negative electrode, emery wheel links to each other with the positive pole of power supply by brush, constitute anode, when the gap between tool-electrode and the emery wheel during, will produce spark discharge, thereby in the spark passage, wink produce a large amount of heat less than discharging gap, reach very high temperature, make bond local melting, gasification and fallen by ablation.Because when emery wheel exists off-centre or out-of-roundness, the gap on the outer surface of grinding wheel bond and tool-electrode plane was unequal when it rotated a circle, regulating this gap makes the bond of super-abrasive grinding wheel diameter major part produce spark discharge, the not flashing discharge of the bond of smaller-diameter portion, thereby the bond of ablation emery wheel eminence, along with the bond that continues to carry out eccentric part of processing is removed, thereby expose abrasive particle, reach and reduce the purpose that abrasive particle is controlled intensity.
(2) when satisfying formula 1. the time, promptly occurring as Fig. 2. situation about (a) showing, when the emery wheel abrasive particle contacted with tool-electrode, g was still greater than g
d, then electric spark can't produce, and electric spark can not be finished the purpose to emery wheel dressing.Utilize the mechanical shaping mode to carry out shaping this moment, to remove outstanding abrasive particle.What adopt here is roll extrusion shaping method, and it installs as Fig. 2. (b), the used shaping emery wheel of shaping process is a brake type carborundum roller.It mainly makes the outstanding abrasive particle fragmentation of eccentric part and comes off by shearing force, thereby electric discharge dressing is proceeded, and finally reaches the purpose of shaping.
In the electric spark-mechanical compound shaping process, adopt the circle of eddy current displacement sensor and amesdial monitoring emery wheel to beat respectively.Because the metal bonded wheel surface mainly is made of metallic bond and abrasive particle, eddy current displacement sensor only can record the profile of the wheel face that is made of metallic bond, amesdial can record the comprehensive circle of the wheel face that is made of metallic bond and abrasive particle and beat, and the difference between the two just can be represented the height of protrusion of abrasive particle.
Because wheel face is scraggly and has idioelectric abrasive material in metallic bond, this will produce error to the measurement result of eddy current displacement sensor, and checking learns that the measure error of eddy current displacement sensor in this test is within ± 3 μ m through test of many times.Equally, the rough and uneven in surface measurement result to amesdial of wheel face also produces certain influence, but this influence can reduce by the statistical average of repeatedly measuring.The present invention marks 20 points at the first-class branch of emery wheel circumference, and duplicate measurements three times uses mean value as final result.The error of this method is greatly about ± 2 μ m.
In the inventive method, before not carrying out emery wheel dressing, at first beat and measure, beat respectively as shown in the figure by the emery wheel circle that current vortex sensor and amesdial record respectively at the initial circle of employed bronze binding agent ultra hard abrasive wheel.By Fig. 4. (a) and (b) are as can be known, at emery wheel not during shaping, the emery wheel circular runout that utilizes dual mode to record is more or less the same, can be similar to and think identical, therefore can think the surface that the outstanding metallic bond of abrasive particle of emery wheel eccentric part constitutes, promptly do not form bigger chip space, need at first carry out electric discharge dressing.
The emery wheel circular runout that records according to current vortex sensor is 36.33 μ m, carries out the thick shaping of electric spark.Through behind 1.5 hours electric discharge dressings, show in the on-line monitoring system that discharge current is zero substantially, substantially not having electric spark this moment produces, the feeding emery wheel is then found after some sparks occurring, rapidly disappear, find that behind the survey tool electrode disappearance of electric spark is because electrode surface is caused by worn.At this moment, the circle that adopts current vortex sensor and amesdial the to record emery wheel respectively again result that beats is illustrated in Fig. 4. (c), in (d).As shown in Figure 4, metallic bond is by ablation, and the outstanding bond surface of super hard abrasive abrasive particle causes electric spark can't need to adopt brake type carborundum roll dresser to carry out shaping to its shaping.
Through behind 2 hours the mechanical shaping, the circle that records emery wheel with amesdial and current vortex sensor is beated as Fig. 4 again. (e), shown in (f), also do not reach the required plastic precision of emery wheel this moment.Then also need carry out half smart and finishing shape with step same as described above to emery wheel respectively, finally this bronze binding agent ultra hard abrasive circle of taking turns is beated respectively the result that records by current vortex sensor and amesdial as Fig. 4. (g), shown in (h).Repair super-abrasive grinding wheel with this compound shaping method, its precision can reach about 6 μ m, but this is enough to satisfy the instructions for use of coarseness emery wheel.
As known from the above, the present invention is a kind of electric spark-mechanical compound shaping method of metal bindnig agent extra hard abradant sand wheel, it has solved metal bindnig agent extra hard abradant sand wheel effectively, the shaping problem of coarseness metal bindnig agent extra hard abradant sand wheel particularly, its plastic precision can reach 6 μ m, can satisfy instructions for use fully.
Description of drawings
Among Fig. 1, (a) be the sustainable situation (g＜g that carries out of electric discharge dressing stage electric discharge dressing
d) schematic diagram, (b) be electric discharge dressing device schematic diagram;
Among Fig. 2, (a) be the unsustainable situation (g＞g that carries out of electric discharge dressing in mechanical full line stage
d) schematic diagram, (b) be brake type carborundum trimming device schematic diagram;
Fig. 3 is the structured flowchart of on-line monitoring system;
Fig. 4 (a)-(h) is a shaping process medium plain emery wheel circular runout change procedure diagram.
In described accompanying drawing:
The 1-metallic bond, the 2-abrasive particle, 3-pole clearance (g),
The 4-tool-electrode, 5-high frequency direct current pulse power source, the 6-metal bonded wheel,
The 7-brush, 8-nozzle, 9-workbench.
The specific embodiment
Adopting granularity is the bronze binding agent ultra hard abrasive wheel of 100/120#, and grinding wheel diameter is 200mm, and width is 10mm.
Compound shaping can reach at the highest grinding speed on the high-speed plane grinding machine of 100m/s and carry out.
The electric spark-mechanical compound shaping condition:
(1) electric discharge dressing device:
1. tool-electrode: material is the plate electrode of brass;
2. working solution: high speed water-based milling liquid;
3. power supply: high frequency direct current pulse power source, voltage are 60V, 90V, 120V third gear, peak inrush current 20A, and high level lasting time: 1 μ s-100 μ s, low duration: 1 μ s-100 μ s, pressure limiting resistance is 18 Ω;
4. carbon-point brush-system;
(2) mechanical shaping device: GIN-DTM100 brake type carborundum roll dresser is produced in Taiwan;
In the electric discharge dressing stage, adopt reciprocal flat electric discharge dressing mode, the linear velocity of emery wheel is 60m/s (can be 55m/s-65m/s), table feed speed is 10m/min (can be 8m/min-12m/min); In order to guarantee plastic precision, need the different electrical guiding rule of size employing according to the circular runout of emery wheel, in conjunction with the required plastic precision that reaches of coarseness emery wheel, as shown in table 1 in the electrical guiding rule parameter that each shaping stage is adopted:
The electrical guiding rule parameter that each stage adopts during table 1 electric discharge dressing
| Stage | Output voltage (V) | Discharge cycle (μ s) | Dutycycle (%) |
| Thick shaping | 120 | 100 | 80 |
| Half finishing shape | 90 | 100 | 50 |
| Finishing shape | 60 | 40 | 20 |
The mechanical shaping stage before using brake type carborundum roll dresser to carry out shaping, need be fixed on the magnetic force workbench, and gyroaxis is parallel with grinding wheel spindle; During shaping, emery wheel rotates, and workbench is done reciprocating feed motion, the linear velocity ratio of freeing wheel and emery wheel remain 1: 100 (can be 1: 90-110), each stroke all feed once, each amount of feeding is 5 μ m-10 μ m.Use grinding fluid in the shaping process, to keep emery wheel and freeing wheel moistening.The implementation step of thick shaping, half finishing shape, finishing shape is identical in the table 1, is the electrical quantity difference that is adopted.Using time between them is: when the emery wheel circle is beated and no longer reduced when adopting the shaping of thick shaping electrical quantity, adopt half finishing shape electrical quantity, and the like.
(3) monitoring system:
For accurately, monitor abrasive wheel electric spark-mechanical compound shaping process easily, the online monitoring system of a cover has also been set up in this research, the composition of this system as shown in Figure 3, mainly contain two effects: discharge voltage when 1. Hall voltage sensor and Hall current sensor are gathered electric discharge dressing in real time and discharge current, with reflection electric discharge dressing process, thereby can suitably control the size of discharging gap, to avoid zero load, arcing even short circuit phenomenon, reach purpose to the electric discharge dressing process monitoring;
2. eddy current displacement sensor is based on the non-contact displacement transducer that the principle of eddy current effect is made, it is by probe, jumper, fore-lying device is formed, can accurately measure static and dynamic relative displacement variation between measured body (must be metallic conductor) and the probe end face, and be processed into the output of the corresponding signal of telecommunication, therefore available its monitored main profile by the wheel face that metallic bond covered in real time, thereby monitor the shaping progress in real time, control the electric discharge dressing progress by different electrical guiding rules, thereby the shaping of emery wheel efficiently and is accurately carried out.
Claims (3)
1, a kind of electric spark-mechanical compound shaping method of metal bindnig agent extra hard abradant sand wheel is characterized in that, this method is:
At first emery wheel is carried out electric discharge dressing, can't generate until electric spark;
Adopt brake type carborundum roller to carry out mechanical shaping then, to outstanding abrasive particle is worn, promptly height of protrusion is zero;
Above-mentioned electric discharge dressing and mechanical shaping process were gone round and begun again about two hours, till plastic precision can't further reduce, reduced the electrical guiding rule parameter;
Repeat described electric discharge dressing and mechanical shaping process more in regular turn, till making emery wheel reach below the required plastic precision 8 μ m.
2, according to the electric spark-mechanical compound shaping method of the described metal bindnig agent extra hard abradant sand wheel of claim 1, it is characterized in that, described electric discharge dressing adopts reciprocal flat electric discharge dressing mode, and the linear velocity of emery wheel is that 55m/s-65m/s table feed speed is 8m/min-12m/min; Tool-electrode is flat brass electrode, and working solution is the high speed water-based milling liquid, and power supply is the high frequency direct current pulse power source, its peak inrush current 20A; Adopt the electrical guiding rule parameter of following table in each shaping stage according to the size of the circular runout of emery wheel:
Stage Output voltage (V) Discharge cycle (μ s) Dutycycle (%)
Thick shaping 120 100 80
Half finishing shape 90 100 50
Finishing shape 60 40 20
3, according to the electric spark-mechanical compound shaping method of the described metal bindnig agent extra hard abradant sand wheel of claim 1, it is characterized in that, described mechanical shaping adopts brake type carborundum roll dresser, emery wheel rotates and workbench is done reciprocating feed motion during shaping, freeing wheel remains 1 with the linear velocity ratio of emery wheel: 90-110, each stroke all feed once, each amount of feeding is 5 μ m-10 μ m, use grinding fluid in the shaping process, to keep emery wheel and freeing wheel moistening.
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