高航,郭天博,彭灿,王宣平,李伟秋,林海生.丝锥刀具旋转磨粒流去毛刺和钝化抛光技术[J].表面技术,2023,52(3):299-307.
GAO Hang,GUO Tian-bo,PENG Can,WANG Xuan-ping,LI Wei-qiu,LIN Hai-sheng.Deburring and Passivation Polishing Technology of Tap Tool with Rotary Abrasive Flow[J].Surface Technology,2023,52(3):299-307
丝锥刀具旋转磨粒流去毛刺和钝化抛光技术
Deburring and Passivation Polishing Technology of Tap Tool with Rotary Abrasive Flow
  
DOI:10.16490/j.cnki.issn.1001-3660.2023.03.027
中文关键词:  丝锥刀具  旋转磨粒流抛光  去毛刺  刃口钝化
英文关键词:tap tool  rotary abrasive flow polishing  deburring  passivation of tool edge
基金项目:
作者单位
高航 大连理工大学 机械工程学院 精密与特种加工教育部重点实验室,辽宁 大连 116024 
郭天博 大连理工大学 机械工程学院 精密与特种加工教育部重点实验室,辽宁 大连 116024 
彭灿 大连理工大学 机械工程学院 精密与特种加工教育部重点实验室,辽宁 大连 116024 
王宣平 大连理工大学 机械工程学院 精密与特种加工教育部重点实验室,辽宁 大连 116024 
李伟秋 汇专科技集团股份有限公司,广州 510662 
林海生 汇专科技集团股份有限公司,广州 510662 
AuthorInstitution
GAO Hang School of Mechanical Engineering,Key Laboratory of Precision and Non-traditional Machining Technology under the Ministry of Education, Dalian University of Technology, Liaoning Dalian 116024, China 
GUO Tian-bo School of Mechanical Engineering,Key Laboratory of Precision and Non-traditional Machining Technology under the Ministry of Education, Dalian University of Technology, Liaoning Dalian 116024, China 
PENG Can School of Mechanical Engineering,Key Laboratory of Precision and Non-traditional Machining Technology under the Ministry of Education, Dalian University of Technology, Liaoning Dalian 116024, China 
WANG Xuan-ping School of Mechanical Engineering,Key Laboratory of Precision and Non-traditional Machining Technology under the Ministry of Education, Dalian University of Technology, Liaoning Dalian 116024, China 
LI Wei-qiu Conprofe Technology Group Co., Ltd., Guangzhou 510662, China 
LIN Hai-sheng Conprofe Technology Group Co., Ltd., Guangzhou 510662, China 
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中文摘要:
      目的 高效、低成本地消除丝锥、铰刀、钻头、铣刀等金属加工刀具磨削后产生的表面毛刺、亚表面烧伤等加工缺陷,实现刀具的高效钝化抛光。方法 基于磨粒流加工(AFM)技术,提出一种刀具旋转磨粒流抛光(R–AFM)原理和方法。通过模拟仿真方法获得优化的刀具运动轨迹,进一步研发可装夹40把刀具的多工位旋转磨粒流高效抛光专用设备;以高速钢丝锥为研究对象,选用新研制的GC磨料介质作为钝化抛光介质,采用正交实验设计法, 通过极差分析和方差分析,探究工件转速、加工时间、磨粒粒径及磨粒质量分数等工艺参数对刃口钝圆半径的影响规律;再选用正交试验获得的工艺参数组合,采用自主研制的WS和GC磨料介质,分别对丝锥刀具进行钝化抛光试验,分析2种新型磨料介质的钝化抛光特性;最后,基于前面的实验结果和理论分析,优选刀具钝化抛光复合加工的工艺参数,并验证刀具的钝化抛光效果。结果 各工艺参数对刀具刃口钝圆半径的影响程度依次为刀具回转速度、钝化抛光时间、磨粒质量分数和粒度。高硬度的GC磨料介质具有材料去除率高、对刃口的钝化能力较强等特点。在保持切削刃锋利度的前提下,采用低硬度的WS磨料介质,其毛刺去除效果更好。采用优化的工艺参数和自主研制的WS、GC磨料介质,对新加工的丝锥分别进行了1.5 min和1 min的组合抛光,加工后丝锥表面的毛刺得以完全去除,表面磨削烧伤痕迹显著消减,表面粗糙度Sa可从0.73 μm降至0.26 μm,刃口圆角半径可控制在企业要求的5 μm以内,刃口得到了有效修整,且避免了刀具刃口的“过顿”现象,抛光效率平均可达20支/min。结论 旋转磨粒流抛光技术与装备能高效去除刀具表面的毛刺,有效地改善了刃口加工缺陷,为复杂结构成型刀具等零件的高质、高效钝化抛光加工提供了一条新途径。
英文摘要:
      The work aims to efficiently and cost-effectively eliminate the burr and subsurface burn on the blade surface caused by the grinding of metal working tools such as taps, reamers, drills and milling cutters, and to realize the efficient passivation and polishing treatment of the tool. Therefore, based on abrasive flow machining (AFM) technology, the polishing principle and method of tool rotary abrasive flow (R-AFP) was proposed in the paper. The optimized tool trajectory was obtained by simulation method with ADAMS application, and the multi-station rotary abrasive flow high-efficiency polishing machine was developed which can be used to polish 40 tools at the same time. With high-speed steel tap as the research object, a new self-developed GC abrasive medium was selected for passivation and polishing, the orthogonal experimental design method was adopted to explore the influence of processing parameters such as workpiece speed, processing time, abrasive grain size and abrasive grain mass fraction on the radius of the blunt circle of the cutting edge by range analysis and variance analysis. Using the combination of process parameters obtained by orthogonal test, the passivation and polishing test of tap tool was carried out respectively with the self-developed WS and GC abrasive media, and the passivation and polishing characteristics of the two kinds of abrasive media were analyzed. Experimental results showed that the influence degree of each process parameter on the passivation polishing effect of rotary abrasive flow was as follows:rotating speed of tool, passivation polishing time, mass fraction of abrasive grains and abrasive grains' size; the result of variance analysis was consistent with that of range analysis; the optimal combination of technological parameters with the highest edge passivation efficiency was as follows:tool rotating speed 200 r/min, processing time 60 s, abrasive particle mass fraction 50%, abrasive particle size 180# in the range of various technological parameters. GC abrasive medium with high hardness had high material removal rate and strong passivation ability to the edge and low hardness. WS abrasive media provided better burr removal while maintaining cutting edge sharpness. Using the optimized process parameters, the new machined taps were polished for 1.5 min and 1min respectively with the self-developed WS and GC abrasive media. The burrs on the surface of the taps were completely removed and the burn marks on the surface of the taps were significantly reduced by twice passivation polishing. Also, the passivated surface roughness was reduced from Sa 0.73 μm to Sa 0.26 μm, the corner radius of the tap edge after passivation polishing can be controlled within 5 μm, the phenomenon of excessive passivation of cutting edge was avoided, and the average polishing efficiency was about 20 sticks/min. In this paper, a creative method of multi-position combined polishing is proposed, the rotary abrasive flow polishing technology can effectively remove the burrs on the tool surface and improve the machining defects of the cutting edge. The newly developed tool passivation polishing machine has better use effect and higher application value. A new way for high-quality and efficient polishing and passivation for complex structural forming tools is presented by the research results.
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