外文翻譯--精密與超精密磨削技術

1、<p>　　精密與超精密磨削技術</p><p>　　摘要: 磨削在現(xiàn)代制造業(yè)中占有重要地位，技術發(fā)展迅速,國內(nèi)外都采用超精密磨削、精密修整、微細磨料磨具進行亞微米級以下切深磨削的研究，以獲得亞微米級的尺寸精度。當前磨削除向超精密、高效率和超硬磨料方向發(fā)展外，自動化也是磨削技術發(fā)展的重要方向之一。本文就精密和超精密磨削，砂帶磨削,磨削自動化進行了研究與論述.</p><p>　　

2、關鍵詞: ELID磨削技術, 砂帶磨削,磨削自動化</p><p><b>　　、</b></p><p>　　Precise and ultra microfinishing technology</p><p>　　Abstract：The grinding holds the important status in the modern

3、manufacturing industry, the technological development is rapid, domesticand foreign all uses the ultra microfinishing, the precise conditioning, the tiny grinding compound grinding tool carries on the submicron level&l

4、t;/p><p>　　to undercut the deep grinding the research, obtains the submicron levelthe size precision.Outside the current grinding except to ultra precise, the high efficiency and the ultra hard grinding compoun

5、d direction develops, the automation also is one of grinding technological development important directions.This article on precise and the ultra microfinishing, the belt grinding, the grinding automation has conducted t

6、he research and the elaboration。</p><p>　　Key word: ELID grinding technology, belt grinding, grinding automation</p><p>　　1 精密與超精密磨削技術</p><p>　　國內(nèi)外都采用超精密磨削、精密修整、微細磨料磨具進行亞微米級以下切深磨削的研

7、究，以獲得亞微米級的尺寸精度。微細磨料磨削，用于超精密鏡面磨削的樹脂結合劑砂輪的金剛石磨粒平均直徑可小至4 μm。日本用激光在研磨過的人造單晶金剛石上切出大量等高性一致的微小切刃，對硬脆材料進行精密磨削加工，效果很好。超硬材料微粉砂輪超精密磨削主要 用于磨削難加工材料，精度可達0.025 μm。日本開發(fā)了電解在線修整(ELID)超精密鏡面磨削技術，使得用超細微(或超微粉)超硬磨料制造砂輪成為可能，可實現(xiàn)硬脆材料的高精度、 高效率的超精密

8、磨削。作平面研磨運動的雙端面精密磨削技術，其加工精度、切除率都比研 磨高得多，且可獲得很高的平面度, 在工具和模具制造中，磨削是保證產(chǎn)品的精度和質量的最后一道工序。技術關鍵除磨床本身外、磨削工藝也起決定性的作用。在磨削脆性材料時，由于材料本身的物理特性，切屑形成多為脆性斷裂，磨劑后的表面比較粗糙。在某些應用場合如光學元件，這樣的粗糙表面必須進行拋光，它雖能改善工件的表面粗糙度，但由于很難控制形狀精度，拋光后經(jīng)常會降低。為了解決這一矛盾，

9、在80年代末日本和歐美的眾多公司和研究機構相繼</p><p>　　(1）塑性磨削 它主要是針對脆性材料而言，其命名來源出自該種工藝的切屑形成機理，即磨削脆性材料時，切屑形成與塑性材料相似，切屑通過剪切的形式被磨粒從基體上切除下來。所以這種磨削方式有時也被稱為剪切磨削（Shere Mode Grindins）。由此磨削后的表面沒有微裂級形成，也沒有脆必剝落時的元規(guī)則的凹凸不平，表面呈有規(guī)則的紋理。 </p&

10、gt;<p>　　塑性磨削的機理至今不十分清楚在切屑形成由脆斷向逆性剪切轉變?yōu)樗軘?，這一切削深度被稱為臨界切削深度，它與工件材料特性和磨粒的幾何形狀有關。一般來說，臨界切削深度在100μm以下，因而這種磨削方法也被稱為納米磨削（Nanogrinding）。根據(jù)這一理論，有些人提出了一種觀點，即塑性磨削要靠特殊磨床來實現(xiàn)。這種特殊磨床必須滿足如下要求： </p><p>　　l）極高的定位精度和運動精

11、度。以免因磨粒的切削深度超過100μm時，導致轉變?yōu)榇嘈阅ハ鳌?</p><p>　　2）極高的剛性。因為塑性磨削的切削力遠超過脆性磨削的水平，機床剛性太低，會因切削力引起的變形而破壞塑性切屑形成的條件。 </p><p>　　對形成塑性磨削的另一種觀點認為切削深度不是唯一的因素，只有磨削溫度才是切屑由脆性向塑性轉變的關鍵。從理論上講，當磨粒與工件的接觸點的溫度高到一定程度時，工件材料的局

12、部物理特性會發(fā)生變化，導致了切屑形成機理的變化。作者從實踐中找到了支持這種觀點的許多證據(jù)：比如在一臺已經(jīng)服役20多年的精度和剛度不高的平面磨床上磨削SiC陶瓷，用40O0#的金剛石砂輪。工件表面粗糙度小于Rq5μm，表面上看不到脆斷的痕跡。另外德國亞琛工業(yè)大學的Konig教授作了如下試驗，在普通的車床上，用激光局部加熱一個SiN陶瓷試件，即能順利地進行車削。這些實驗均間接地說明溫度對切屑形成機理有決定性的影響。 </p>

13、<p>　?。?）鏡面磨削 顧名思義，它關心的不是切屑形成的機理而是磨削后的工件表面的特性。當磨削后的工件表面反射光的能力達到一定程度時，該磨削過程被稱為鏡面磨削。鏡面磨削的工件材料不局限于脆性材料，它也包括金屬材料如鋼、鋁和鉬等。為了能實現(xiàn)鏡面磨削，日本東京大學理化研究所的Nakagawa和Ohmori教授發(fā)明了電解在線修整磨削法ELID（Electrolytic In-Process Dressing）。 </p&g

14、t;<p>　　鏡面磨削的基本出發(fā)點是：要達到境面，必須使用盡可能小的磨粒粒度，比如說粒度2μm乃至0.2μm。在ELID發(fā)明之前，微粒度砂輪在工業(yè)上應用很少，原因是微粒度砂輪極易堵塞，砂輪必須經(jīng)常進行修整，修整砂輪的輔助時間往往超過了磨削的工作時間。ELID首次解決了僅用微粒度砂輪時，修整與磨削在時間上的矛盾，從而為微粒度砂輪的工業(yè)應用創(chuàng)造條件。</p><p>　　ELID(Electrolyt

15、ic In-Process Dressing)磨削是在磨削過程中，利用非線性電解修整作用和金屬結合劑超硬磨料砂輪表層氧化物絕緣層對電解抑制作用的動態(tài)平衡，對砂輪進行連續(xù)修銳修整，使砂輪磨粒獲得恒定的突出量，從而實現(xiàn)穩(wěn)定、可控、最佳的磨削過程，它適用于硬脆材料進行超精密鏡面磨削。ELID磨削技術以其效率高、精度高、表面質量好、加工裝置簡單及加工適應性廣等特點，在日本已較廣泛用于電子、機械、光學、儀表、汽車等領域。</p>&

16、lt;p>　　ELID磨削原理是金屬結合劑超硬磨料砂輪與電源正極相接做陽極，工具電極做陰極，在砂輪和電極的間隙中通過電解磨削液，利用電解過程中的陽極溶解效應，對砂輪表層的金屬基體進行電解去除，從而逐漸露出嶄新鋒利的磨粒，形成對砂輪的修整作用：同時形成一層鈍化膜附著于砂輪表面，抑制砂輪過度電解，從而使砂輪始終以最佳磨削狀態(tài)連續(xù)進行磨削加工。所以該技術將砂輪修整與磨削過程結合在一起，利用金屬基砂輪進行磨削加工的同時利用電解方法對砂輪進

17、行修整，從而實現(xiàn)對硬脆材料的連續(xù)超精密鏡面磨削。</p><p>　　ELID鏡面磨削過程可分為準備階段、電解預修銳階段、在線電解修整動態(tài)磨削階段和光磨階段。準備階段主要是對砂輪進行動平衡和精密整形，減小砂輪的圓度和圓柱度誤差：預修銳階段使砂輪獲得適當?shù)某鋈懈叨群秃侠淼娜菪伎臻g，并形成一層鈍化膜：動態(tài)磨削階段形成加工表面：光磨階段則進一步提高表面質量。</p><p>　　ELID磨削去除

18、材料的機理與其他鏡面加工有所不同。通常的鏡面加工是通過磨削、研磨和拋光來獲得的。研磨和拋光是以柔性的研磨盤把磨料壓在材料表面并產(chǎn)生相對運動，磨料借助研磨盤的壓力以滾動方式使材料破碎，以滑動和滾動方式去除破碎后的材料。 </p><p>　　而在ELID磨削中，一方面由于磨粒固著在結合劑中，對于單顆粒的固著磨粒而言，其有效磨削尺寸只有磨粒尺寸的1/3，磨粒主要以微切削的方式去除材料，所以造成的破碎區(qū)要小得多：另一方

19、面，砂輪表面形成具有一定厚度和彈性且容納有脫落磨料的鈍化膜，成為一種具有良好柔性的研磨膜。精磨時，由于進給量很小，鈍化膜的厚度遠大于磨料的出刃高度，使砂輪基體表層磨料在磨削中不可能直接與工件接觸，砂輪上覆蓋的這層鈍化膜將代替金屬基砂輪參與真正的磨削過程。當電解作用完全抑制時，鈍化膜對工件進行光磨。所以ELID磨削實際上是一種將磨、研、拋合為一體的復合式精密鏡面加工技術，其中磨粒主要是以滑動方式去除工件材料的</p><

20、;p>　　ELID磨削技術是對金屬結合劑超硬磨料砂輪在線修整、修銳的復合磨削技術，它有別于電解磨削、電火花磨削，在精密加工領域獨樹一幟，具有自身的一些顯著特點。</p><p>　　磨削過程具有良好的穩(wěn)定性和可控性，易于實現(xiàn)磨削過程的最優(yōu)化： 加工精度高，表面裂紋少，表面質量好： 適應性廣泛，磨削效率高：裝置簡單，成本低，推廣性強等。</p><p>　　ELID磨削的必備裝置主要有

21、砂輪、電源、電解裝置、電解液和磨床等五個要素。 </p><p>　　ELID磨削對磨床的要求主要是要有較高的主軸回轉精度。 </p><p>　　ELID磨削用砂輪的結合劑應具有良好的導電性和電解性能，而結合劑元素的氧化物或氫氧化物不導電。目前常用的砂輪有鑄鐵纖維結合劑(CIFB)、鑄鐵結合劑(CIB)和鐵粉結合劑(IB)的金剛石砂輪， ELID磨削的電源可以采用直流電源、交流電源、脈沖

22、電源等。電解裝置的主要部分是工具電極。磨床結構不同，工具電極的位置和形狀也不同，電極宜用不銹鋼制造，與砂輪的間隙控制在0. 5～1. 5mm范圍內(nèi)，而且應與機床充分絕緣。工具電極固定在絕緣板上，再用調節(jié)栓將絕緣板固定在砂輪防護罩上。電極上開有蓄水槽，電解磨削液采用中心送液法，依靠重力和離心力充滿電極間隙。 </p><p>　　ELID磨削液兼做電解液，一般采用弱堿性電解質水溶液。但結合劑和磨粒粒度不同，磨削液的

23、主要成分也不同。磨削液對電解過程中形成的鈍化膜的厚度、性質乃至最終的磨削效果都有重要影響。 </p><p>　　ELID磨削技術在我國尚處于研究階段，主要集中在高校，如哈爾濱工業(yè)大學、大連理工大學、西安交通大學、天津大學、西北工業(yè)大學等。哈爾濱工業(yè)大學經(jīng)過幾年的努力，研制成功了ELID磨削專用的脈沖電源、磨削液和砂輪，在國產(chǎn)機床上開發(fā)出平面、外圓和內(nèi)圓ELID磨削裝置，并對多種硬脆材料進行了ELID鏡面磨削的實

24、驗研究。目前正積極推廣普及該技術，實現(xiàn)產(chǎn)品化。國內(nèi)已有十幾家單位應用該技術，如230廠用于加工動壓馬達零件，23所用于相陣雷達互易移相單元陶瓷、微晶玻璃、鐵氧體等航天材料零件加工，8358廠用于光學玻璃非球曲面加工，205所用于光學玻璃加工，華僑大學用于加工大理石，福建南安宏偉陶瓷廠用于加工陶瓷等。 </p><p>　　盡管ELID磨削技術在我國的發(fā)展落后于一些工業(yè)發(fā)達國家，但是ELID磨削技術在國內(nèi)的研究和應

25、用基礎已經(jīng)具備。特別是該技術顯著的特點，尤其適合我國國情。隨著該技術的進一步普及推廣，相信有越來越多的專家和學者認識到這項技術的重要性和它潛在的經(jīng)濟價值，越來越多的企業(yè)重視并采用該技術，從而促進我國傳統(tǒng)產(chǎn)業(yè)的改造和高新技術的發(fā)展。ELID磨削技術作為一種新型的鏡面加工方法，具有廣闊的應用前景和很大的實用價值。</p><p>　　精密與超精密磨削技術</p><p>　　摘要: 磨削在現(xiàn)代

26、制造業(yè)中占有重要地位，技術發(fā)展迅速,國內(nèi)外都采用超精密磨削、精密修整、微細磨料磨具進行亞微米級以下切深磨削的研究，以獲得亞微米級的尺寸精度。當前磨削除向超精密、高效率和超硬磨料方向發(fā)展外，自動化也是磨削技術發(fā)展的重要方向之一。本文就精密和超精密磨削，砂帶磨削,磨削自動化進行了研究與論述.</p><p>　　關鍵詞: ELID磨削技術, 砂帶磨削,磨削自動化</p><p>　　Preci

27、se and ultra microfinishing technology</p><p>　　Abstract：The grinding holds the important status in the modern manufacturing industry, the technological development is rapid, domesticand foreign all uses the

28、 ultra microfinishing, the precise conditioning, the tiny grinding compound grinding tool carries on the submicron level</p><p>　　to undercut the deep grinding the research, obtains the submicron levelthe

29、size precision.Outside the current grinding except to ultra precise, the high efficiency and the ultra hard grinding compound direction develops, the automation also is one of grinding technological development important

30、 directions.This article on precise and the ultra microfinishing, the belt grinding, the grinding automation has conducted the research and the elaboration。</p><p>　　Key word: ELID grinding technology, belt

31、grinding, grinding automation</p><p>　　1 is accurate with rubing the technology of paring ultraprecisionly </p><p>　　Adopt and waste paring ultraprecisionly, repairing accurately both at home an

32、d abroad, it has research that cuts and is rubed pared deeply of under submicro grade that very small abradant is rubed, in order to obtain the size precision of grade of submicro. Very small abradant rub, sharpen, used

33、in ultraprecision surface of the mirror resin sharpened to rub combine pharmaceutical diamond grit of emery wheel average diameter little to 4 μ m very. Japan cuts out a large amount of and waits for hig</p><p

34、>　　(1)Plasticity rubs and pares it mainly regarding fragility material, it names smear metal formation mechanism that the source comes from this kind of craft, rub it while paring the fragility material, it is similar

35、 to plasticity material that the smear metal takes shape, the smear metal is excised from matrices by the grit through the form of shearing. So this kind rubs way of paring and known as shearing and wasting paring (Shere

36、 Mode Grindins) sometimes . Rub surface sharpen, split grade take </p><p>　　Plasticity mechanism sharpened to rub clear in smear metal forming from fragile and broken to shear, change against sex into, mould

37、, break very much so far, all these are pared and known as the borderline to cut the depth deeply, it and work piece material characteristic have something to do with the geometirc form of the grit. Generally speaking, b

38、orderline cut depth under 100μ m, therefore this kind rub, sharpen method known as nanometer rub and sharpen (Nanogrinding) too . According to this t</p><p>　　l)Extremely high localization precision and move

39、ment precision. In case that because result in changing into the fragility and rub and pare when the cutting of the grit exceeds 100μ m deeply. </p><p>　　2)Extremely high rigidity. Because plasticity rubs t

40、he cutting strength pared exceeds the fragility and rubs the level pared far, the lathe rigidity is too low, will arising from cutting strength deformation destroy plasticity terms that smear metal form. </p><

41、;p>　　Rub another view pared to show to the plasticity of forming that it is not the only factor to cut the depth, it is a smear metal key from fragility to plasticity transition to only rub the temperature of paring.

42、Theoretically, when the temperature that grit and contact of the work piece are lighted is high to certain extent, some physical characteristic of the work piece material will change, has caused the change of smear metal

43、 formation mechanism. The author has found a lot of evidences of sup</p><p>　　( 2) The surface of the mirror is as its name suggests rubed and pared, what it cared about is not but the mechanism that smear m

44、etal forms rubs the characteristic of the surface of work piece after paring. When the surface of work piece after rubing and paring reflects all ability and becomes certain, it's time to rub the course of paring and

45、 known as the surface of the mirror to rub and pare. The surface of the mirror rubs the work piece material pared and does not confine to the fragility mat</p><p>　　The surface of the mirror rubs the basic p

46、oint of departure pared: Should reach it the border, must enable and use the granularity of grit as small as possible, for example granularity 2μ m and even 0.2μ m. Before ELID invents, one degree of emery wheels is bein

47、g employed little commercially in the particle, the reason is that particle one degree of emery wheels is extremely easy to stop up, the emery wheel must be often repaired, repair assisting time and often exceeding the w

48、orking time to par</p><p>　　ELID(Electrolytic In-Process Dressing) It is in the course of rubing and paring to rub and pare, utilize non-linear to repair function with metal combine pharmaceutical ultra hard

49、 abradant emery wheel top layer oxide insulating barrier to electrolytic dynamic equilibrium of inhibitory activity while being electrolytic, repair and repair sharp the emery wheel continuously, make the grit of emery w

50、heel obtain invariable outstanding quantity, thus realize steady, controllable, best rubing the cours</p><p>　　ELID rub, sharpen principle whether metal combine pharmaceutical ultra hard abradant emery wheel

51、 and power positive pole meet and make positive pole, the tool electrode is made the negative pole, through rubing and paring the liquid electrolytically in the interval of emery wheel and electrode, utilize the positive

52、 pole in electrolytic course to dissolve the effect, remove the metal matrices of the top layer of emery wheel electrolytically, thus the brand-new and sharp grit emerges gradually, fo</p><p>　　ELID surface

53、of the mirror rub, sharpen course can divide into preparatory stage, electrolytic to build sharp stage, online to repair, rub the stage of sharpening and only rub stage dynamically while being electrolytic in advance. Pr

54、eparatory stage mainly carry on the dynamic equilibrium to the emery wheel and have a facelift accurately, reduce one degree of errors of round degree and cylinder of the emery wheel: Repair sharp stage highly making the

55、 emery wheel get appropriate producing the edge</p><p>　　ELID rubs and pares the mechanism and other surface of the mirror which removes the material to process to some extent differently. The common surface

56、 of the mirror is processed and got by rubing paring, grinding and polishing. It is by grinding one and pressing abradant on the surface of material and producing the relative motion of flexibility to grind with the poli

57、shing, abradant makes the material broken by way of rolling through the pressure of grinding one, the material after it is broken </p><p>　　In ELID rubs and pares, on one hand because the grit is firm in com

58、bining pharmaceutical, as to firm grit of the single particle, it rubs and pares 1/3 with grit size of size effectively, the grit removes materials in a manner to cut a little mainly, so the broken district caused is muc

59、h smaller: On the other hand, the surface of emery wheel is formed to have certain thickness and elasticity and hold coming off the passivation membrane of the abradant, becoming one has grinding the membrane of g</p&

60、gt;<p>　　ELID rub, sharpen technology to combine to metal pharmaceutical ultra hard abradant emery wheel repair, build sharp complex rub the technology of sharpening online, it is electrolytic to rub, sharpen for

61、it to different from, electric spark rub, sharpen, in accurate to process field take the course of its own, some prominent characteristics with oneself. </p><p>　　Rubing the course of paring has good stabili

62、ty and controllability, it is apt to realize rubing optimization the most which pare the course: The machining accuracy is high, there is few crackle of surface, the surface is of high quality: Adaptability is extensive,

63、 rub and pare with high efficiency: The device is simple, with low costs, the popularizing is strong. </p><p>　　What ELID rubs and pares must fit and mainly have five key elements such as emery wheel, power,

64、 electrolytic device, electrolytic liquid and grinding machine fully. </p><p>　　ELID should have higher main shafts to turn the precision round to pare requirements for grinding machine to rub. </p>

65、<p>　　ELID should have good electric conductivity and electrolytic performance to pare with combination pharmaceutical of the emery wheel to rub, the oxide or caustic combining the pharmaceutical element does not c

66、onduct. The present commonly used emery wheel has casting iron fibers to combine pharmaceutical (CIFB) , the casting iron combines pharmaceutical (CIB) Combine pharmaceutical (IB) with the iron powder Diamond emery wheel

67、,it rub ELID ones that sharpen can last direct current source, alternati</p><p>　　ELID rub, sharpen liquid and concurrently make electrolytic liquid, generally adopt slightly alkaline electrolytic aqueous so

68、lution. But it is different in granularity to combine the pharmaceutical and grit, it is different to rub the principal ingredients which pare the liquid. Rub, sharpen liquid to passivation thickness, property, rubing, s

69、harpening result have important influence final of membrane that electrolytic course form. </p><p>　　ELID rubs the technology of paring and is still at the stage of studying in our country, mainly concentra

70、tes on the university, for instance polytechnical university of Harbin, institute of technology of Dalian, university of Xi'an Communications University, Tianjin, northwest polytechnical university,etc.. Harbin polyt

71、echnical university pass efforts for a few years, succeed in developing ELID rub, sharpen the special-purpose pulse power, rub and sharpen liquid and emery wheel, develop level, o</p><p>　　Though ELID rubs a

72、nd pares developing and lagging behind some industrially developed countries in our country of technology, but ELID rubs the technology of paring to already possess in domestic research and application foundation. Especi

73、ally this characteristic with prominent technology, is especially suitable for the national conditions of our country. As the further popularization of this technology is popularized, believe that more and more experts a