柔性轮磨抛工艺参数对大尺寸钛合金圆孔表面质量的影响研究

Study on the influence of polishing process parameters of flexible wheel on the surface quality of large-size titanium alloy round hole

  • 摘要: 针对现有刚性加工方式在提升大尺寸钛合金圆孔(直径大于100 mm)时表面质量精度受限且工艺流程复杂的问题,提出一种柔性轮离心磨抛加工方式。首先,建立单颗磨粒磨削钛合金三维数值仿真模型,探究不同主轴转速下的磨削区域温度场和磨削力变化规律,开展钛合金磨削加工机理研究和工艺参数优化。其次,探究不同柔性轮材料对圆孔表面粗糙度、形貌和孔径的影响,分析工艺参数与表面粗糙度的关系。最后,提出钛合金圆孔柔性离心磨抛表面质量控制方法。结果表明,磨削温度集中于变形区,当转速增加1.39倍时,磨削温度上升2.1倍,而磨削力受转速影响较小;随着砂带页轮磨粒目数提高1倍,表面粗糙度降低了28%,达到0.48 μm且更柔软的棉布轮能使表面粗糙度显著降低40%,表面划痕更细腻。该研究验证柔性轮磨抛钛合金材料的工艺可实现性,为提高大尺寸孔径表面质量提供一种有效方式。

     

    Abstract: Aiming at the problem that the accuracy of surface quality is limited and the process flow is complex when the existing rigid processing method is used to improve the large-size titanium alloy round hole (diameter is greater than 100 mm), the centrifugal grinding and polishing processing method by the flexible wheel is proposed. Firstly, a three-dimensional numerical simulation model of single abrasive grain, grinding titanium alloy, is established to explore the variation law of temperature field and grinding force in grinding area under different spindle speeds, and the research of the grinding mechanism and the process parameter optimization of titanium alloy are carried out. Secondly, the effects of different flexible wheel materials on the surface roughness, morphology and pore size of the circular hole are investigated, and the relationship between process parameters and surface roughness is analyzed. Finally, the surface quality control method of titanium alloy circular hole by the flexible centrifugal grinding and polishing is proposed. The results show that the grinding temperature is concentrated in the deformation zone. When the rotational speed increases by 1.39 times, the grinding temperature increases by 2.1 times, but the grinding force is less affected by the rotational speed. As the mesh of the abrasive belt wheel is doubled, the surface roughness is reduced by 28%, reaching 0.48 μm. The softer cotton wheel can significantly reduce the surface roughness by 40% and the surface scratches are more delicate. This study verifies the process feasibility of flexible wheel grinding and polishing for titanium alloy materials, and provides an effective way to improve the surface quality of large aperture.

     

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