渐开线磁极组研磨双面的相对角度试验

刘杰; 焦安源; 薄啟帆; 丁云龙; 陈燕

doi:10.13394/j.cnki.jgszz.2023.0185

渐开线磁极组研磨双面的相对角度试验

doi: 10.13394/j.cnki.jgszz.2023.0185

1.
辽宁科技大学机械工程与自动化学院, 辽宁鞍山 114051
2.
辽宁科技大学应用技术学院, 辽宁鞍山 114051

基金项目: 辽宁省教育厅项目（LJKZ0295）；辽宁省自然科学基金项目（2019-ZD-0029）。

详细信息

作者简介:
焦安源，男，1978年生，博士，教授、硕士研究生导师。主要研究方向：磁粒研磨加工、精密铣削加工及相关自动化设备开发。E-mail：jay@ustl.edu.cn

中图分类号: TG176
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- 被引次数: 0
出版历程
- 收稿日期: 2023-09-03
- 修回日期: 2023-11-21
- 录用日期: 2023-11-28
- 刊出日期: 2024-10-01

Experiments on relative angles of grinding two sides of involute pole groups

1.
School of Mechanical Engineering and Automation, University of Science and Technology Liaoning, Anshan 114051, Liaoning, China
2.
School of Applied Technology, University of Science and Technology Liaoning, Anshan 114051, Liaoning, China

摘要

摘要: 为解决钛合金TC4表面的凸起、划痕和微裂纹等缺陷问题，提出一种对立磁极组产生相对角度的双面磁粒研磨方式，从而提高其研磨效率。在双面旋转研磨试验的基础上，对磁性磨粒进行受力分析，通过渐开线排布磁石的设计，对比该磁极下磁感应强度的变化，进而分析对立磁极组产生相对角度的磁场梯度对表面质量的影响规律，最后进行表面粗糙度变化检测，以及对研磨前后的工件表面微观形貌检测。结果表明：采用渐开线排布磁石，覆盖面积相对较大并且磁场分布均匀；相对角度$ {10}{\text{°}} $双面研磨时，磁场梯度变化较大，有利于磁性磨粒的及时翻滚。工件正面的表面粗糙度R_a由初始的0.458 μm降至0.116 μm，表面高度差由原始的43.3 μm降至7.8 μm；工件反面的表面粗糙度R_a由初始的0.434 μm降至0.111 μm，表面高度差由原始的44.2 μm降至8.4 μm。通过渐开线排布磁石产生相对角度的研磨加工，工件表面的凸起、划痕、沟壑和微裂纹等缺陷得到明显改善，工件双面同时研磨，提高了研磨效率。
- 双面磁粒研磨 /
- 磁极设计 /
- 相对角度 /
- 梯度对比 /
- 表面质量
Abstract: Objectives : Titanium alloys are increasingly widely used in the aerospace field, and their research and development significantly influence the advancement of military aircraft, civil aviation, engines, and other high-tech equipment. However, titanium alloy are challenging to machine due to theri small deformation coefficient, low thermal conductivity, and the high temperatures generated during traditional cutting methods, which leads to tool wear. As a result, parts often have low precision, and surface quality is generally poor. This study proposes a double-sided magnetic abrasive finishing (MAF) method using opposing magnetic pole sets with adjustable relative angles to address surface defects—such as bumps, scratches, and microcracks—on the surface of titanium alloy TC4 and to improve its grinding efficiency. Methods: This study compares three types of lined magnets and introduces an involute-lined magnet design. Based on this design, opposing magnetic pole sets are used to generate an initial relative angle between them. The effects of different relative angles on double-sided MAF are tested to determine whether this method can improve the magnetic induction intensity and promote a more uniform distribution of abrasives. The results show that this approach addresses the challenges of poor abrasive fluidity and the inability of abrasives to tumble effectively. Additionally, the simultaneous grinding of both sides of the workpiece enhances processing efficiency, effectively removes the surface defects of the workpiece, and improves the grinding efficiency and surface quality. Results: The application of involute-lined magnets with a relative angle for double-sided MAF yields improved processing results under the following test conditions: magnetic pole group speed of 600 r/min, processing gap of 2 mm, magnetic abrasives size of 150 μm, and a relative angle of 10°. After 30 minutes of grinding, the surface roughness of the front side of the titanium alloy is reduced from R_a 0.458 μm to R_a 0.116 μm, and the surface height variation decreases from 43.3 μm to 7.8 μm. The reverse side also shows improvements, with surface roughness decreasing from R_a 0.434 μm to R_a 0.111 μm, and surface height variation reducing from 44.2 μm to 8.4 μm. Conclusions: The use of involute-lined magnets to create a relative angle for double-sided grinding effectively improves surface defects, such as scratches and grooves, on the workpiece. This method also significantly enhances grinding efficiency compared to single-sided grinding. The involute arrangement of magnets minimizes variations in magnetic induction intensity, which improves grinding efficiency and ensures a more uniform distribution of the magnetic field. This uniformity results in better adsorption of magnetic abrasives and enhanced grinding quality. When grinding at a relative angle of 10°, the magnetic field gradient changes significantly, covering a wider area with stronger magnetic induction. This variation in magnetic field gradient faciliates the tumbling of magnetic abrasives and the timely renewal of cutting edges, ultimately improving processing performance.
- double-sided magnetic particle grinding /
- magnetic pole design /
- relative angle /
- gradient contrast /
- surface quality

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图 1 双面研磨加工原理

Figure 1. Principle of double-sided finishing

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图 2 单个磁性磨粒受力分析

Figure 2. Force analysis of single magnetic abrasive

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图 3 渐开线示意图

Figure 3. Schematic diagram of involute

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图 4 渐开线排布磁石示意图

Figure 4. Schematic diagram of involute magnet arrangement

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图 5 磁石排布仿真对比

Figure 5. Comparison of simulation of magnet arrangement

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图 6 两侧磁极组旋转角度示意图

Figure 6. Schematic diagram of rotation angle of magnetic pole group on both sides

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图 7 磁极组不同相对角度和磁场梯度变化

Figure 7. Variation of magnetic field gradient with different relative angles and magnetic pole group

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图 8 试验装置实物图

Figure 8. Physical diagram of the test setup

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图 9 表面粗糙度随时间的变化曲线

Figure 9. Curve of surface roughness with time

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图 10 工件正面研磨前后形貌对比和高度差对比图

Figure 10. Comparison of morphology and height difference before and after front grinding of workpiece

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图 11 工件反面研磨前后形貌对比和高度差对比图

Figure 11. Comparison of morphology and height difference before and after back grinding of workpiece

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表 1 磁场模拟仿真参数

Table 1. Parameters of magnetic field simulation

参数名称	数值或类型
磁极组Ⅰ转速 n₁ / (r·min⁻¹)	600
磁极组Ⅱ转速 n₂ / (r·min⁻¹)	600
磁极组转向	顺时针
两侧磁极组距离 s / mm	4
初始相对角度 λ / (°)	10

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表 2 磁场模拟仿真参数

Table 2. Parameters of magnetic field simulation

参数名称	数值或类型
磁极组Ⅰ转速 n₁ / (r·min⁻¹)	600
磁极组Ⅱ转速 n₂ / (r·min⁻¹)	600
磁极组转向	顺时针
两侧磁极组距离 s / mm	4
参考线长度 a / mm	40
初始相对角度 λ / (°)	0、10、20

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表 3 试验条件

Table 3. Test conditions

参数名称	数值或类型
工件材料	钛合金TC4板
工件尺寸 / mm	100.0 × 100.0 × 0.8
加工间隙 l / mm	2
研磨液	劳力恩SR-9911水基式研磨液6 mL
磁性磨粒	Fe与Al₂O₃混合烧结磨料，粒径为150 μm
磁极组Ⅰ转速 n₁ / (r·min⁻¹)	600
磁极组Ⅱ转速 n₂ / (r·min⁻¹)	600
磁极组转向	顺时针
初始相对角度 λ / (°)	0、10、20
磨粒填充量 Q / g	30
加工时间 t / min	30

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