基于转子动力学的纳米微粒自适应内喷涂层磨削润滑机理研究

Due to the severe cutting friction, high gridning temperature and high pressure in cutting environment, solid lubrication coating of grinding wheels can not continue to maintain, easy to plug from the wheel and not real-time associated with grinding status. So, the thesis of adaptive coated grinding wheel by real-time sprayed inside with solid layered nanoparticle would be bring forward. The working principle is as follows: the grinding wheels would be coated with layered nanoparticles of good lubricating properties by inside spray real-time, and the lubricant layer parameters on grinding wheel surface would be controled by the feedback signal of grinding statue online, finally the lubricant layer on grinding wheel surface can be holded for long with good performance and matched real-time with grinding statue. The main research contents include: the generate and maintain mechanism of the nanoparticles lubricant coating by inside interaction would been exposed, and explored online nanoparticle inside spray adaptive coating technology would be study, the operated mechanism of the layerd solid adaptive nanoparticles coated by inside spray would be illustrated. The significance of this project is focused on: perfect green grinding theory, carry out green grinding, supplement theoretical of green cutting and guidance for the construction and development of green manufacturing disciplines.

针对固体润滑剂软涂层砂轮磨削时，润滑涂层在高温磨削环境下不能持续保持、易堵塞砂轮、未与磨削状况实时智能关联等问题，提出了基于转子动力学的纳米微粒在线内喷涂自适应涂层砂轮干式磨削加工的构想。其机理为：将润滑性能良好的纳米微粒通过内部喷涂工艺在线涂附在砂轮表面，并由实时监控磨削状况信号反馈控制涂层的形成，从而实现润滑涂层可持续保持，涂层性能良好且与磨削状况保持实时关联的目的。主要研究内容包括：揭示纳米微粒润滑涂层在内部驱动力作用下的黏结生成与保持机制，探索在线内喷自适应纳米微粒涂层磨削润滑机理，阐明纳米微粒在线内喷涂自适应涂层砂轮磨削润滑性能。本项目的研究意义在于：探索纳米微粒润滑涂层润滑磨削加工理论，为绿色制造工艺学科建设与发展提供理论指导，为实现绿色磨削加工具有重要的意义。

磨削时一般多采用切削液浇注磨削弧区，达到降低磨削温度、提高砂轮寿命和工件表面质量。为了提高切削液的润滑性能，往往还加入添加剂，添加剂多为有毒物质。另磨削过程中砂轮高速旋转所形成的气流屏障阻碍切削液进入磨削弧区，同时切削液在磨削高温的作用下产生大量有毒烟雾，对环境危害很大。. 基于砂轮磨削时高速旋转等特点，开展了固体润滑剂粉末内喷磨削润滑原理研究，完成了预装固体润滑剂粉末内喷单层电镀CBN砂轮、连续供给固体润滑剂粉末内喷单层电镀CBN砂轮和冷却介质智能在线喷涂控制系统的设计和研制，开展了内喷砂轮的磨削性能和磨削TC4钛合金仿真和实验研究，分析了润滑涂层对磨削温度、磨削表面粗糙度、磨削力和砂轮磨损等方面的影响，探索了固体润滑剂粉末的润滑涂层生成、保持机制以及润滑机理。. 通过内喷砂轮智能控制系统进行磨削TC4钛合金的理论、仿真和实验研究，结果表明：设计制造的预装固体粉末内喷砂轮出粉量均匀，能够形成润滑涂层润滑减摩效果良好；连续供粉内喷涂层砂轮磨削时，根据温度测试结果控制供粉系统将石墨粉末输送到砂轮内腔，再通过内腔叶轮的作用使润滑剂粉末经由微孔析出到砂轮表面，形成固体润滑涂层，润滑涂层能够减小摩擦力，提高了砂轮切削能力。降低了磨削温度，控制固体粉末的使用量，提高了内喷砂轮的切削能力和寿命。根据磨削仿真和实验测量结果，内喷涂层砂轮与干磨削相比，磨削温度降低30%，磨削表面粗糙度降低约20%，实现在线内喷涂自适应涂层润滑磨削加工，为固体粉末润滑涂层在磨削环境下的应用提供支持。。. 通过固体润滑剂粉末内喷砂轮涂层生成与保持过程、在线内喷技术、涂层自适应控制技术和固体润滑剂粉末涂层磨削润滑机理的研究，在固体润滑剂粉末涂层的制备技术、生成与保持机制、润滑机理和磨削特性等方面有一定的研究进展，为完善绿色磨削理论，实现绿色磨削加工具有重要的意义。