面向钴基合金覆层自由曲面模具的凝胶砂轮光化学高效加工新方法

Irregular and high hardness surfaces of alloy based on Cobalt cladding freeform mold always make machining process a tough job. To this point, a new high efficiency machining method based on gel wheel and photochemistry effect has been presented. According to deformation principle of gel under electro-mechanical coupling effect, gel wheel has been developed under the support of gel driver array to freeform surface of mold. Based on Floyr’s gel swelling theory and Neo-hookean energy theory, we are trying to obtain deformation rule and dynamic characteristic of gel wheel. Meantime, gel test platform will be established by optical measurement method for optimizing design parameters of gel wheel. Faced with high hardness surface, abrasives will be soft-consolidated on the outer film of wheel by binder to maintain cutting ability. Based on multiscale mechanical theory, we contribute to find out dynamic characteristic of shape-shear abrasives under support of array. According to photoelastic’s stress-light and multicolor ladder-shape theory, abrasives dilatancy analysis platform will be built to conclude excellent cutting situation for abrasives. To alloy based on Cobalt layer, a machining method at the aid of photochemistry has been presented. we try to find out multi-group chemical reaction mechanism and build calculation model between photon and electronic to reveal materials removal mechanism of gel wheel. Furthermore, a machining platform with gel wheel and photochemistry effect will be established for optimizing the technology line and process parameters. Our project will supply theory and technology for freeform mold machining process and leave a technology reference for high-efficient machining to alloy based on Cobalt.

针对钴基合金覆层自由曲面模具不规则和高硬度的加工难点，提出一种凝胶砂轮光化学高效加工方法。面向模具自由曲面，利用凝胶力电耦合形变特性，设计凝胶驱动器阵列支撑砂轮，基于Floyr凝胶溶胀理论和Neo-hookean能量理论，探究凝胶砂轮形变机理和动力学特性，并基于光学测量方法搭建凝胶性能测试平台进行验证，优化砂轮设计参数；面向高硬度表面，在砂轮套膜表层黏结磨粒层以保证切削力度，基于多尺度力学分析理论，探究多点阵列支撑下的磨粒群结构化剪胀动力学特性，基于光弹颗粒彩色梯度分析方法，搭建磨粒群剪胀分析平台验证理想切削条件；针对钴基合金覆层，提出光化学辅助砂轮加工方法，探究多组分化学反应机理，建立光子与电子产率的计算模型，揭示光化学辅助下的凝胶砂轮材料去除机理，搭建凝胶砂轮光化学自动化加工平台，优化技术线路和工艺参数。本项目为模具自由曲面精密加工提供理论依据与技术支撑，为钴基合金的高效去除提供参考。

针对钴基合金覆层自由曲面模具不规则和高硬度的加工难点，提出l了一种凝胶砂轮光化学高效加工方法。基于凝胶驱动器力电耦合形变原理，探究了凝胶驱动器阵列支撑下的砂轮形变机理和动力学特性；基于多尺度力学分析理论，探究了结构化剪胀态磨粒群力链构型和动态特性，总结了凝胶驱动器阵列支撑下的磨粒群理想切削条件；面向钴基合金覆层，探究了多组分化学反应机理，建立了光子与电子产率的计算模型，揭示了光化学辅助下的凝胶砂轮材料去除机理。在技术上：设计并制作了形变性能优异的凝胶驱动器单元，优化了驱动器构型和阵列布局；搭建了磨粒群剪胀模拟试验平台，依据彩色梯度分析方法，分析了磨粒群微观动力学特性和力链构型；搭建了凝胶砂轮光化学自动化加工平台，总结加工规律，优化工艺线路，提升加工效率。本项目的开展可为钴基合金覆层自由曲面模具精密加工提供理论依据与技术参考，也为钴基合金在其他领域的应用提供新的加工思路。