宋沛鸿,郭磊,刘天罡,曹蕾蕾,陈瑱贤,张静.基于反刍类动物臼齿仿生的平面磨具形貌结构设计与性能研究[J].表面技术,2024,53(2):140-149, 167.
SONG Peihong,GUO Lei,LIU Tiangang,CAO Leilei,CHEN Zhenxian,ZHANG Jing.Ruminant Molar-inspired Design and Performance Study of Textured Abrasive Lapping Tool[J].Surface Technology,2024,53(2):140-149, 167 |
| 基于反刍类动物臼齿仿生的平面磨具形貌结构设计与性能研究 |
| Ruminant Molar-inspired Design and Performance Study of Textured Abrasive Lapping Tool |
| 投稿时间：2023-01-09 修订日期：2023-06-19 |
| DOI：10.16490/j.cnki.issn.1001-3660.2024.02.013 |
| 中文关键词: 仿生设计 平面磨具 表面形貌结构 研磨加工性能 磨削液流动性 磨粒滞留 |
| 英文关键词:bionic design lapping tool surface texture and topography lapping performance slurry fluid flow abrasive retention |
| 基金项目:国家自然科学基金(51805044);陕西省自然科学基础研究计划(2022JM-254);中国博士后科学基金(2020M673318);机械传动国家重点实验室开放基金(SKLMT-MSKFKT-202006) |
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| Author | Institution |
| SONG Peihong | School of Construction Machinery, Chang'an University, Xi'an 710061, China |
| GUO Lei | School of Construction Machinery, Chang'an University, Xi'an 710061, China;State Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing 400044, China |
| LIU Tiangang | Zhong Tian Guide Control Technology Company, Xi'an 710010, China |
| CAO Leilei | School of Construction Machinery, Chang'an University, Xi'an 710061, China |
| CHEN Zhenxian | School of Construction Machinery, Chang'an University, Xi'an 710061, China |
| ZHANG Jing | School of Construction Machinery, Chang'an University, Xi'an 710061, China |
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| 中文摘要: |
| 目的 提高平面研磨加工效率及加工质量。方法 提取了反刍类动物臼齿齿面形貌特征，设计了一种模块化分布式平面研磨工具，采用ABAQUS分析了无特征规则排布磨具与仿生特征排布磨具在研磨抛光过程中对工件压力分布均匀性的影响;采用Fluent分析了仿生特征排布磨具形貌结构对磨削液流动性的影响;利用3D打印技术制备了仿生特征排布磨具与无特征规则排布磨具并进行了对比实验，通过响应面分析法讨论了转速、压力、表面结构特征等因素对磨具研磨性能的影响。结果 仿真结果表明，与无特征规则排布磨具相比，在4 N研磨压力下仿生特征排布磨具具有更优的工件表面应力分布均匀性;磨削液在磨具形貌特征间隙入口的流速为2.400 m/s时，与其他特征磨具相比，仿生特征模块化排布磨具的形貌特征间隙出口平均流速提升了29.45%。实验结果表明，与无特征规则排布磨具相比，在同等工艺下，使用仿生特征模块化排布磨具研磨的铝合金试件表面粗糙度由0.301 μm降至0.188 μm，下降了17.94%;当研磨压力为5 N时，材料去除速率由1.44 μm/min提升至1.93 μm/min，提升了34.47%。结论 平面磨具的形貌结构特征设计与排布对研磨过程中的工件接触压力分布、磨削液流动性具有重要影响。与无特征规则排布磨具相比，在相同工艺条件下臼齿仿生特征模块化排布磨具能够更有效地提升加工效率及加工质量。 |
| 英文摘要: |
| In the lapping process, as the lapping tool is in direct contact with the workpiece, the design of the morphological characteristics and the arrangement of textured patterns of the lapping tool have a decisive influence on the processing quality and efficiency. However, the textured pattern and morphological feature design in conventional lapping tools are usually simple and unitary, which makes them susceptible to problems such as uneven distribution of lapping force and abrasive particles, poor flowability of the lapping fluid, and inefficient utilization of abrasive particles resulting in low machining efficiency. This research combines bionic design to improve the lapping tool's morphological characteristics and pattern arrangement to enhance the lapping performance regarding materials removal rate and surface quality. Inspired by the chewing behavior of ruminants, a modular distributed surface lapping tool was designed by extracting the morphological features from the molar tooth surface. Then the finite element method was used to analyze the uniformity of the equivalent pressure distribution on the workpiece during the lapping. The regular arrangement lapping tool without featured morphological design and the modular arrangement lapping tool with bionic design were comparatively studied. Furthermore, the influence of the slurry fluid flow and the abrasive particles' retention behavior was analyzed using the Fluent software based on hydrodynamic simulation. Besides theoretical analysis and computer simulation, a set of verification experiments were also carried out. For a comparative experimental study of lapping aluminum alloy specimens, the light-cured 3D printing method was used to prepare a modular arrangement lapping tool with bionic design features and a regular arrangement lapping tool without any featured design. The quantitative effects of factors such as rotational speed, pressure, and morphological design features on the lapping performance of the tools were discussed by response surface analysis. The results of the comprehensive theoretical study and experimental data show that, compared with regular arrangement lapping tools without any featured design, the uniformity of pressure distribution on the contact surface of the workpiece under 4 N lapping force of modular arrangement lapping tool with bionic design features was improved. The grey level variance of the binarized image processing of the contact stress distribution was reduced to 3.78, indicating the improvement in uniformity of lapping force distribution. Moreover, when the flow rate of lapping fluid at the gap inlet of the morphological feature was taken as 2.400 m/s, the average flow rate at the gap outlet of the modular arrangement tool with bionic feature design was 0.211 m/s, which was 29.45% higher than that of other tools. With the same process conditions, the machined surface roughness Ra of the aluminum alloy specimens lapped with the molar-inspired bionic design tool was reduced from 0.301 μm to 0.188 μm, which was an improvement of 17.94% compared with that of the regular tools. An improvement of 34.47% was also achieved in the material removal rate when the lapping force was set at 5 N. In all, the design of the lapping tool's morphological features and pattern arrangement has an important influence on the force distribution, fluid flow, and effective abrasive retention during the machining process. Therefore, the proposed modular arrangement of the molar tooth bionic design tool can effectively improve material removal efficiency and surface finish quality compared with the regular lapping tools, which provides a new idea for the development of ultra-precision surface machining technology. |
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