精密磨削微小毛刺形成及高速切削/磨削去毛刺机理研究

Carry out single abrasive scratch test and grinding experiment, study on the chip formation and the mechanical-thermal coupling in fourth deformation zone, analyze the burr morphology, characteristics and distribution of deformation, then establish burr formation model to predict burr formation, distribution and the work hardening characteristics. Study on the micro burr removal mechanism by high speed cutting and grinding, establish burr removal model based on plastic strain gradient theory, and the model of strain, hardening, and residual stress at workpiece edge. Analyze the deformation and hardening characteristics at the cutting area of workpiece, and then establish critical standards for working edge damage. Based on the result, establish correlation model of grinding process and deburring process, optimize the grinding parameters and deburring parameters, and establish the deburring parameters decision system based on grinding process. Carry out experiments, using small feed high speed cutting / grinding technology to remove micro-burr at working edge, ensure the working edge profile accuracy and surface integrity. The research results would provide theoretical guidance and technical support for online deburring of micro burr in precision grinding, and promote the development of precision machining technology.

开展单颗磨粒刻划试验和磨削试验，研究磨屑的形成规律，分析第四变形区热力耦合情况，分析毛刺形貌、特性和分布规律，建立磨削微小毛刺的预测模型，预测毛刺的形态、分布规律以及加工硬化等特性；研究微小毛刺的超高速切削和磨削去除机制，基于应变塑性梯度理论，建立微小毛刺去除模型；建立工件棱边应变模型、硬化模型以及残余应力模型，研究去毛刺过程中切削/磨削变形区域工件材料的变形和硬化特点，建立棱边损伤（轮廓和表面完整性）的临界准则，获得可行的去毛刺工艺范围。在此基础上，建立磨削工艺和去毛刺工艺的关联模型，提出优化的磨削加工参数以及去毛刺工艺方案，建立基于磨削加工工艺的去毛刺工艺决策系统。开展工艺试验，采用微进给超高速切削/磨削技术，实现工作边微小毛刺的在线精确去除，确保工作边轮廓精度和表面完整性。研究成果可为精密磨削加工中微小毛刺的高效在线去除提供理论指导和技术支持，对推动精密加工技术的发展具有积极意义。

在金属的切削和磨削加工过程中不可避免会产生毛刺现象，是零件常见的缺陷之一，其控制和精确去除是精密加工领域重要的研究课题。本项目针对精密磨削产生的微小毛刺，采用仿真和试验相结合的方法研究磨削微小毛刺的形成过程以及磨削加工参数对于毛刺尺寸的影响规律，以抑制微小毛刺的形成。采用车削方式去除毛刺，开发去除微小毛刺的专用设备和工艺，针对轴类零件磨削端面的微小毛刺提出在线精确去毛刺方法，确保棱边轮廓精度的前提下，能够有效地去除工件端面的微小毛刺。