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磁粒研磨镍基高温合金群孔切出毛刺的研究∗

  • 丁浩东1

    机 构：

    1. 辽宁科技大学机械工程与自动化学院 鞍山 114051

    ×
  • ， 张国富1

    机 构：

    1. 辽宁科技大学机械工程与自动化学院 鞍山 114051

    ×
  • ， 焦安源2

    机 构：

    2. 辽宁科技大学应用技术学院 鞍山 114051

    ×
  • ， 韩冰1

    机 构：

    1. 辽宁科技大学机械工程与自动化学院 鞍山 114051

    ×

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

Study on Exit Burrs in Group Holes of Nickel-based Superalloy by Magnetic Abrasive Finishing

  • DING Haodong1

    Affiliation：

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

    ×
  • ， ZHANG Guofu1

    Affiliation：

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

    ×
  • ， JIAO Anyuan2

    Affiliation：

    2. School of Applied Technology, University of Science and Technology Liaoning, Anshan 114051 , China

    ×
  • ， HAN Bing1

    Affiliation：

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

    ×

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

作者简介:

丁浩东,男,1993年出生,硕士研究生。主要研究方向为精密加工与特种加工。E-mail:dhd860@126.com;

焦安源(通信作者),男,1978年出生博士,教授,硕士研究生导师。主要研究方向为磁粒研磨加工、精密铣削加工及相关自动化设备开发。E-mail:cnjoay@163.com

中图分类号:TG176;TB114

DOI:10.11933/j.issn.1007-9289.20210331004

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目录contents

    摘要

    为解决镍基高温合金 GH3128 群孔切出毛刺难去除的问题,基于磁粒研磨法开展毛刺去除试验研究。 对镍基高温合金 GH3128 钻孔加工后孔缘毛刺进行分类,基于磁粒研磨法分析典型毛刺去除机理,并提出群孔毛刺去除的研磨轨迹和磁极形状初步方案。 开展磁粒研磨群孔试验研究,分析主轴转速和磨粒平均粒径对切出毛刺去除的影响。 结果表明:在主轴转速为 1500 r/ min、磁性磨料平均粒径 250 μm、进给速度 2 mm/ s、磁性磨粒填充量 30 g、加工间隙 2 mm 的加工条件下,研磨 40 min 后,群孔切出毛刺平均高度由原始的 141 μm 降至 20. 5 μm,毛刺的平均宽度从原始 350 μm 降至 163 μm。 规划研磨轨迹、磁极开矩形槽以及优化研磨参数的方法,使镍基高温合金 GH3128 群孔切出毛刺得到了很好的去除,此加工方案可为群孔切出毛刺的去除提供参考。

    Abstract

    In order to solve the problem of difficult removal of the exit burrs of the nickel-based superalloy GH3128 group holes, an experimental study on burr removal was carried out based on the magnetic abrasive finishing( MAF) process. The exit burrs after drilling in the nickel-based superalloy GH3128 were classified, the removal mechanism of typical burr was analyzed based on the MAF process, and a preliminary burr removal plan of the group holes for the grinding trajectory and shape of magnetic pole was proposed. The experimental study of the group holes was carried out by use of magnetic abrasive, and the effects of spindle speed and average abrasives size on the removal of exit burrs were analyzed. The results show that as the spindle speed is 1500 r/ min, the average abrasives size is 250 μm, the feed rate is 2 mm / s, the filling amount of abrasives is 30 g, and the machining gap is 2 mm, after 40 minutes of grinding, the average height of the exit burrs from the group holes decreased from the original 141 μm to 20. 5 μm,and the average width of the exit burrs decreased from the original 350 μm to 163 μm. According to the planning grinding trajectory, machining the rectangular slot on the magnetic pole and optimizing the grinding parameters, the exit burrs in group holes of the nickel-based superalloy GH3128 are well removed. The processing scheme provides a novel reference for the removal of exit burrs in group holes.

  • 0 前言

  • 镍基高温合金不仅具有良好的抗氧化、抗疲劳和抗腐蚀能力,还有较高的蠕变强度和持久强度,通常应用于600℃以上的工作环境中[1-2]。目前,镍基高温合金凭借其良好的综合性能,广泛应用于航空航天、石油化工、机械制造、海洋环保等领域[3-5]。尤其在航空航天领域,高温镍基合金GH3128材料多被用于核心部件,上面开有细密的气膜孔,为了预防燃烧室筒体的震荡燃烧和过热[6-7]。但是,孔的棱边处往往存在毛刺,阻碍废料、积碳的排放,并且毛刺受高温熔化也会阻塞气膜孔,使发动机过早磨损,降低其可靠性和稳定性, 最终引发严重的后果[8]。因此,孔切出毛刺的去除以及孔表面质量的光整对孔类零部件的使用性能具有一定的保障作用。王贵成等[9] 以切削运动和进给运动方向为基准,对切削毛刺进行了分类,建立了金属切削中进给方向毛刺生成模型,提出几种控制和减少进给方向毛刺的新方法。杨世春[10]系统地介绍了19种去毛刺方法,并且详细描述了去除毛刺方法的特点和应用实例。陈春增等[11] 利用磁粒研磨技术对镍基高温合金( Inconel718) 表面进行处理,获得了较高的表面质量,达到了加工要求。焦安源等[12] 基于磁粒研磨加工机理,通过仿真软件模拟分析,优选加工工艺对TC4钛合金孔棱边毛刺进行去除,提高了加工效率,改善了表面形貌,但只针对单个孔切出毛刺去除开展了研究,内容未涉及群孔。卢晓红等[13] 镍基高温合金微铣削试验,虽有效地去除了槽壁的毛刺, 但极大地影响了槽的尺寸精度,在后期处理中极难被修复。

  • 本文提出采用磁粒研磨来去除镍基高温合金钻削群孔切出毛刺方案,对毛刺类型和去除机理进行分析,通过改善研磨轨迹和圆柱形轴向磁极开矩形槽的方法来改善磁感应强度的分布。磁性磨粒在磁场力的作用下,随磁极自转和水平移动的作用对群孔毛刺进行去除,使群孔毛刺受力状态呈多向性,也将有利于研磨效率的提升。

  • 1 毛刺的类型分析

  • 钻削加工中,产生的毛刺通常有两种类型:切入进给方向毛刺和切出进给方向毛刺。切入进给方向毛刺尺寸一般较小,根部厚度较薄,而切出进给方向毛刺的尺寸较大,根部厚度较大[14]。另外,根据毛刺的外观形状可将孔切出进给方向毛刺分为Ⅰ、Ⅱ、Ⅲ三种类型[15]。

  • Ⅰ型毛刺:毛刺向孔内凹陷,也称作负毛刺。一般情况下,此类毛刺的高度和根部厚度都非常小。 Ⅰ型毛刺对工件精度和应用性能的影响不是很大, 但对工件的定位精度和装配精度等会很容易造成影响。

  • Ⅱ型毛刺:毛刺凸出加工孔,附在孔的周围。此类毛刺高度小于孔的半径,毛刺厚度一般小于毛刺高度。 Ⅱ型毛刺对工件精度和应用性能有一定的影响,在工件的精密与超精密加工中,Ⅱ型毛刺必须去除。

  • Ⅲ型毛刺:此类毛刺凸出工件终端面,附在加工孔周围。 Ⅲ型毛刺的尺寸比前二者都大,此类毛刺高度接近孔的半径,必须被去除。

  • 高温镍基合金GH3128钻削制孔过程中,Ⅰ型和Ⅲ型都已经得到了很好的控制,而Ⅱ型毛刺去除成为提升孔缘质量的研究重点。归纳Ⅱ型毛刺一般有三种主要形态,如图1所示,Ⅱ-A型毛刺较为独立呈颗粒状,且与孔缘的接触区域较小;Ⅱ-B型毛刺呈薄壁状,高度远大于毛刺厚度;Ⅱ-C型毛刺呈丘状,毛刺抗变形能力强。

  • 图1 Ⅱ型毛刺的三种形态对比

  • Fig.1 Comparison of three forms of type Ⅱ burr

  • 2 毛刺去除机理分析

  • 磁粒研磨技术不仅能对平面、曲面、管件表面进行光整加工,还能够对孔件、环槽等加工区域的毛刺进行去除。研磨加工时,磁性研磨粒子在磁场力的作用下,形成柔性的磁粒刷吸附在磁极的表面,并对毛刺产生一定的压力[16]。磁极转动时,磁粒刷跟随磁极运动,磁性磨粒将对毛刺产生挤压、划擦等切削作用。通常不同类型的毛刺其去除方式不同,毛刺的去除方式主要包括裹挟拉断、疲劳脱落以及磨削去除。

  • 图2a为裹挟拉断,磁性磨粒将毛刺包裹,在磁场力作用下对毛刺挤压,随磁极旋转,毛刺被弯折或拉断。图2b为疲劳脱落,磁粒刷作用于毛刺时产生变形,对毛刺产生不同方向的挤压力,随磁极旋转毛刺反复受到不同方向的挤压作用,产生疲劳,最终脱落。图2c为磨削去除,磁性磨粒在磁场力作用下对毛刺表面产生压力,随磁极旋转对毛刺进行微量切削。

  • 图2 毛刺的去除方式分析

  • Fig.2 Analysis of burr removal methods

  • 3 研磨轨迹分析

  • 研磨轨迹决定着磁粒刷的运动方式,从而改变了磁性磨料对切出毛刺的作用力,影响了研磨效果。基于分析软件仿真不同工况下单颗磁性磨粒的运动轨迹,观察其运动过程以及疏密程度。图3是主轴转速为1 500r/min,进给速度为2mm/s,步数为10 000时单颗磁性磨粒的研磨轨迹,可看出磁极自转的同时也做水平移动,研磨轨迹密集而均匀。

  • 图3 磁极研磨轨迹

  • Fig.3 Magnetic pole grinding track

  • 磁性磨粒研磨切出毛刺时,毛刺受力状态分析如图4所示。其中,磁极的转速为 n1,磁极的进给速度为 v,毛刺受作用力的表达式如下:

  • Fa=Fa1+Fa2Fb=Fb1+Fb2
    (1)

  • 式中,Fa1为磁极进给速 v 施加给毛刺的推力,该力的方向与进给速度 v 同向;Fa2为磁极转速n 1 施加给毛刺的力,该力的方向与圆柱磁极的圆周相切;由式(1)得 Fa为 Fa1和 Fa2的合力,Fa的方向指向孔的外部。圆柱磁极运动到位置2对孔切出毛刺的作用力如图4所示,Fb、Fb1、Fb2 的原理与Fa、Fa1、Fa2 的原理相同,并且对应值也相近似,而Fb 的方向指向孔的内部。随着研磨时间的不断持续,使得毛刺在工件表面的合力方向呈现周期性变化。毛刺有时会向孔内弯曲,有时会向孔外弯曲。当变形超过一定的允许值时,将导致一些毛刺出现裂纹,并最终破裂和脱落。此外,这种周期性的作用力也会引起毛刺疲劳并掉落。基于毛刺受力的理论分析,从中可得出改善轨迹可以提高研磨质量和效率。

  • 图4 毛刺受力状态分析

  • Fig.4 Analysis of burr force state

  • 4 试验研究

  • 4.1 试验原理

  • 毛刺去除原理如图5所示。磁石由夹具固定, 通过刀柄连接在数控加工中心主轴上,磁极吸附在磁石上。磁极与工件之间留有2mm的加工间隙, 将磁性磨料与研磨液混合均匀,吸附在磁极上。磁性磨粒沿着磁场梯度均匀排列成具有一定切削性能的磁粒刷,压附在孔件表面[17-19]。随主轴旋转,磁粒刷不断扫刷群孔表面,促使磁性磨粒持续翻滚、更新,其切削刃不停地碰撞、划擦孔件表面,进而将毛刺去除[20]。

  • 图5 毛刺去除原理

  • Fig.5 Schematic of burr removal

  • 4.2 试验装置与条件

  • 采用上腾远航V8数控加工中心( 主轴最高转速为12 000r/min)搭建毛刺去除试验装置,如图6所示。工件由螺栓紧固在模具上,并通过紧固装置夹持在工作台上。开矩形槽磁极吸附磁性磨料, 沿着磁力线的方向形成柔性的磁粒刷[ 21],从图中可以看出磁粒分布空隙呈“ 米” 字形,与磁极开槽一致。磁性磨粒在自转运动和水平移动共同作用下,实现对群孔切出毛刺和工件表面的光整加工。

  • 图6 毛刺去除装置

  • Fig.6 Device of burr removal

  • 采用镍基高温合金GH3128, 长100mm, 宽100mm,厚0.8mm,孔直径为 ϕ4mm,孔距a与b均为5mm,呈9行9列分布。磁石为钕铁硼永磁体,一次可以研磨5行5列共25个孔。磁性磨料由铁和Al2O3 按质量比2 ∶ 1均匀混合、压制成型、烧结、粉碎制成。研磨试验条件如表1所示。工艺参数组合如表2所示。试验过程中,每隔8min更换一次磁性磨料和研磨液;加工完成后,工件通过超声波清洗机清洗并烘干;每组试验取4个孔(如图5所示),采用日本基恩士生产的VHX-500超景深电子显微镜观测其切出毛刺的微观形貌,测量最大毛刺高度和宽度。

  • 表1 磁粒研磨的试验条件

  • Table1 Experimental conditions of magnetic abrasive finishing

  • 表2 磁粒研磨工艺参数

  • Table2 Process parameters of magnetic abrasive finishing

  • 5 结果与分析

  • 5.1 试验因素影响分析

  • 5.1.1 转速对群孔切出毛刺的影响

  • 根据经验初选磁性磨料平均粒径为250 μm,磁性磨料填充量为30g,进给速度为2mm/s时,分析不同磁极转速对群孔切出毛刺去除的影响。

  • 主轴转速对毛刺高度的影响如图7所示,随加工时间的增长,毛刺高度逐渐降低。当主轴转速为2 000r/min时,磁性磨料偏离加工区域聚集在磁极边缘,或飞离加工区域,使研磨压力减小,切削能力减弱, 研磨效果降低, 切出毛刺高度由原始的141 μm降至54 μm。主轴转速为1 000r/min时, 磁极转速降低,磁性磨粒对切出毛刺的研磨、切削次数减少,使群孔切出毛刺高度下降较小,由原始的141 μm降低至46.2 μm。

  • 图7 主轴转速对毛刺高度的影响

  • Fig.7 Effect of spendle speed on burr height

  • 通过试验分析最终得出主轴转速为1 500r/min时毛刺去除效果最佳。

  • 5.1.2 磨料平均粒径对群孔切出毛刺的影响

  • 设定主轴转速为1 500r/min,磁性磨粒的填充量30g,进给速度为2mm/s时,分析不同磨料平均粒径对群孔切出毛刺高度去除的影响,如图8所示, 随加工时间的增长,毛刺高度逐渐降低。当磨料平均粒径为150 μm时,磨料在磁场中受到的磁场力较小,切削作用较弱,特别是对镍基高温合金这种难以继续去除毛刺。随平均粒径的增大,磨料所受磁场力增大,对毛刺的微量切削作用增强,研磨效率提升[22]。磨料平均粒径为350 μm时,毛刺受到较大的研磨压力,在研磨前期,研磨效率较高,毛刺高度下降较快,加工间隙增大,磁粒刷韧性降低,切削能力减弱,另外,磨料粒径过大,使工件表面的切痕较深,表面质量较差[23-24]。试验得出:磨料平均粒径为250 μm时研磨效果最好,毛刺高度由141 μm降至20.5 μm。

  • 图8 磨料平均粒径对毛刺高度的影响

  • Fig.8 Effect of average abrasvies size on burr height

  • 5.2 毛刺形貌变化分析

  • 对比不同研磨工艺参数组合对群孔切出毛刺高度的影响,如图9所示。研磨前期毛刺去除量较高, 研磨效果较好,随加工进行,磨粒的研磨作用力逐渐下降,研磨后期毛刺去除量趋于平稳。

  • 对比不同研磨工艺参数组合对群孔切出毛刺宽度的影响,如图10所示。从图中可以看出,在研磨前期,毛刺宽度迅速下降,这主要是由于磁粒刷与孔的边缘紧密接触,受研磨压力较强,另外,毛刺的部分材料被迅速研磨去除或裹挟脱落。在研磨后期, 毛刺宽度下降速度逐渐减缓,这主要是由于随加工进行,研磨间隙逐渐增大,磨粒对毛刺的研磨作用力减弱,使毛刺宽度去除效率下降。

  • 图9 试验组毛刺高度的比较

  • Fig.9 Comparison of burr height of experiment series

  • 图10 试验组毛刺宽度的比较

  • Fig.10 Comparison of burr width of experiment series

  • 从图9与图10可以看出, 当主轴转速为1 500r/min,进给速度为2mm/s,磨料平均粒径为250 μm,磨料填充量为30g时,毛刺去除效果最好。

  • 利用超景深电子显微镜对试验3的工件进行三维形貌测量,检测其相邻4个孔(如图5所示)的毛刺高度与宽度,为了便于检测和比较,取每个孔毛刺较大位置所处的1/4圆周作为研究对象。

  • 研磨前孔的切出毛刺形貌如图11所示。从图中可以看出,分别绘制穿过毛刺的蓝色的测量线,既能够测量出个该测量线处的毛刺高度,也能测定此处毛刺的宽度。研磨前, 毛刺的平均高度约为141 μm,平均宽度约为350 μm。研磨后孔的切出毛刺形貌如图12所示。研磨加工后,毛刺平均高度约为20.5 μm,平均宽度约为162.1 μm。毛刺平均高度降幅约为85.5%,而毛刺平均宽度降幅约为53.7%,对比可知基于磁粒研磨法对镍基高温合金GH3128群孔进行毛刺去除时,毛刺高度的降幅高于宽度。

  • 图11 研磨前切出毛刺形貌

  • Fig.11 Topography of exit burr before grinding

  • 6 结论

  • (1) 根据毛刺外观形貌,总结出三种毛刺类型, 通过毛刺去除机理分析,归纳出三种类型毛刺的去除方式。在研磨过程中Ⅰ型毛刺的去除方式主要为磨削去除;Ⅱ型毛刺的去除方式以裹挟去除与疲劳脱落为主,磨削去除为辅;Ⅲ型毛刺研磨前期以磨削去除为主,研磨中后期以裹挟去除与疲劳脱落为主, 磨削去除为辅。

  • 图12 试验组3研磨后切出毛刺形貌

  • Fig.12 Topography of exit burr in experiment No.3after grinding

  • (2) 采用传统磁粒研磨法对镍基高温合金群孔切出毛刺进行研磨时,受磁场边缘效应的影响, 磨粒都集中分布在磁极的边缘处,影响研磨质量。通过研磨轨迹规划和磁极开矩形槽可以解决磁场边缘效应,使磨粒分布均匀,毛刺去除效果得到提高。

  • (3) 通过磁粒研磨试验研究,当主轴转速为1 500r/min,进给速度为2mm/s,磨料平均粒径为250 μm,磨料填充量为30g,经过40min研磨后,群孔切出毛刺基本均被去除。

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  • 基本信息

    中图分类号: TG176;TB114
    DOI: 10.11933/j.issn.1007-9289.20210331004

    基金信息

    辽宁省自然科学基金 (2019-ZD-0029)；
    辽宁科技大学骨干教师(601011507-32) 资助项目；
    Supported by Natural Science Foundation of Liaoning Province ( 2019-ZD-0029)；
    University of Science and Technology Liaoning Talent Project(601011507-32).；

    引用信息

    稿件历史

    收稿日期: 2021-03-31

  • 参考文献

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