基于结构化砂轮伺服振动辅助磨削的光伏玻璃表面规则纹理创成方法

Solar glass with textured surfaces is of great importance for the solar energy equipment efficiency, largely influencing the rapid and healthy development of solar industry of China. However, high cost, long production cycle, and uncontrollability of the manufactured solar glass products are the main problems of the current manufacturing techniques. To fix this, a fabrication method of textured solar glass by servo-vibration-assisted grinding with structured grinding wheels is proposed in this project. The methodology takes advantage of both the special structures on the grinding wheel surfaces and controllable material removal behaviors thanks to the servo-vibration motion of the workpiece. The geometrical model of the proposed method, the solution of the inverse problem, the material removal mechanism, the formation mechanism of both surface and subsurface damage are also studied in this project. Besides, based on the conventional abrasive tools, the non-tool-wear, high-efficiency, and good-machinability waterjet machining method is employed to produce structures on the grinding wheel surface. The discrete element method is also used to simulate both the discontinuous structure of the real grinding wheel microstructure and the dynamic response wheel behaviors under the waterjet impact load, so that the structured grinding wheels can be produced with low cost and high quality. The outcomes of this project are expected to not only realise the high-efficiency, low-cost, diverse, and controllable manufacturing of solar glass, but also provide the theoretical methods and technique supports of the energy structure transformation of China.

具有表面规则纹理的光伏玻璃是决定太阳能装置光能采集效率的关键，影响着我国太阳能产业的优质发展。然而，成本高、制备周期长、制得产品质量性能可控性差是目前现有工艺普遍存在的问题。基于此，本项目提出一种基于结构化砂轮伺服振动辅助磨削的光伏玻璃制备方法。该方法利用结构化砂轮特殊的表面结构以及工件伺服振动带来的工件-砂轮间可控的材料去除行为，通过建立加工过程几何运动学模型并对其逆问题进行反解，探究玻璃材料去除以及表面/亚表面损伤形成机理，制备出规则纹理表面。此外，本项目以普通砂轮为基体，利用水射流技术无刀具磨损、高效、加工灵活性高等优势，在砂轮表面加工特定结构，并使用离散元素法对磨粒-结合剂-气孔非连续复杂结构及其在水射流冲击下的动态冲蚀过程进行理论建模，从而实现结构化砂轮的低成本、高质量制备。项目研究成果有望实现光伏玻璃的高效、低成本、多样、可控加工，为我国能源结构转型提供理论手段和技术支持。

本项目围绕基于结构化砂轮伺服振动辅助磨削的光伏玻璃制备方法开展研究，探讨结构化砂轮制备技术与机理、结构化砂轮磨削运动学、光学玻璃表面无损伤磨削机理等。采用NG:YAG脉冲激光光源以及CO2激光光源对树脂-金刚石多材料进行烧结实验，发现多通过方式对烧蚀深度和入口宽度影响明显，材料烧蚀行为包括金刚石石墨化、树脂蓬松、树脂气化等。利用规律制备出多种表面微结构的砂轮，包括直线形、菱形、方形、六边形等。研究了基于NG:YAG脉冲激光可控制备结构化砂轮表面自由曲面阵列特征的技术和理论，给出了可行激光参数选取策略。发明了多通过旋转慢走丝线切割电火花加工的微尺度结构化砂轮可控制备技术，制备出具有多领域功能特性的微尺度结构化砂轮。深入探讨了光学玻璃磨削崩边缺陷，通过引入材料应变率硬化效应，建立了崩边损伤模型，阐明了崩边缺陷形成机理。随磨削速度增大，崩边形态从直线，经过多边形，演变为部分椭圆，直至为全椭圆。本课题研究理论和技术成果对指导光伏玻璃批量生产具有重要价值。项目资助发表高水平SCI论文11篇，待发表1篇。培养博士生3名。项目投入经费29.41万元，支出24.13万元，各项支出基本与预算相符。剩余经费5.28万元。剩余经费计划用于本项目研究后续支出。