百叶轮抛光TC4温度仿真与试验

王丽博; 鲜超; 辛红敏

doi:10.13394/j.cnki.jgszz.2024.0019

百叶轮抛光TC4温度仿真与试验

doi: 10.13394/j.cnki.jgszz.2024.0019

王丽博^1, ,,
鲜超^2,,
辛红敏^2,

1.
河南机电职业学院智慧城市学院, 郑州 451192
2.
西北工业大学机电学院, 西安 710072

基金项目: 国家科技重大专项资助项目（2015ZX04001003）；国家自然科学基金面上项目（51675439）。

详细信息

作者简介:
鲜超，男，1987年生，博士、讲师、硕士研究生导师。主要研究方向：整体叶盘加工技术。E-mail：xianchao1994@163.com

辛红敏，女，1979年生，博士、教授、硕士研究生导师。主要研究方向：航空航天复杂结构件数控智能制造装备及工艺、冷喷涂增材制造、抗疲劳制造技术、物联网与智能交通技术。 E-mail：xhm0330@163.com

通讯作者:
王丽博，女，1984年生，硕士。主要研究方向：机械加工、控制技术。 E-mail：22995305@qq.com

中图分类号: TG580.14;V232.4
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- 被引次数: 0
出版历程
- 收稿日期: 2024-01-25
- 修回日期: 2024-04-29
- 录用日期: 2024-05-24
- 网络出版日期: 2024-05-24
- 刊出日期: 2025-06-30

Temperature simulation and experimental for polishing TC4 with abrasive cloth wheel

WANG Libo^{1
, ,},
XIAN Chao^2
,,
XIN Hongmin^2
,

1.
Smart City College, Henan Mechanical and Electrical Vocational College, Zhengzhou 451192, China
2.
School of Mechanical Engineering, Northwestern Polytechnical University, Xi'an 710072, China

摘要

摘要: 抛光温度是影响零件表面性能的重要因素，尤其会对零件表面残余应力的形成产生关键影响。通过试验测量百叶轮抛光TC4试件的抛光温度，基于矩形移动热源模型建立抛光温度的理论计算模型，并通过ANSYS仿真抛光TC4的表面温度。结果表明：抛光温度随主轴转速、百叶轮压缩量的增大而升高，随进给速度、磨粒目数的增大而降低。柔性抛光温度要显著低于刚性抛光温度，4个工艺参数中百叶轮压缩量的主效应最大，对抛光温度的影响程度最大。抛光温度梯度以正在加工的接触区域向已加工区域逐渐递减，抛光热效应对未加工区域影响较小。通过对比抛光温度测量结果、计算结果和仿真结果，发现仿真值和测量值的偏差率均 < 22%，计算值和测量值的偏差率均 < 17%。
- 百叶轮 /
- 抛光温度 /
- 理论模型
Abstract: Objectives During the polishing and grinding process, a large amount of heat is generated in the contact area between the grinding tool and the workpiece, while the amount of material removed is very small. Most of the heat is transferred to the workpiece, causing a rapid increase in temperature near the surface of the workpiece. This results in adverse effects such as residual tensile stress, white layer, and deformation, which negatively impact the surface quality and performance of parts. Therefore, studying the distribution laws and influencing factors of surface temperature in polishing and grinding, and controlling the processing surface temperature are of great significance. Methods A polishing test platform is built, and polishing temperatures are measured under different process parameters. The measured temperature values are corrected to obtain the actual temperature values. A theoretical model of the temperature field in the polishing contact area is derived based on the rectangular moving heat source model, and a temperature calculation model corresponding to the experimental measurement point is obtained, with the temperature value of that point calculated. The workpiece temperature field distribution during polishing is obtained using ANSYS simulation software and APDL for cyclic loading. The distribution law of the workpiece temperature field is studied, and the internal mechanism of this distribution law is explored. The temperature values corresponding to the experimental measurement points are extracted. The measured, calculated, and simulated values of temperature near the same point in the polishing contact area are compared. Based on the experimental results, single factor influence law figures of four process parameters on polishing temperature are drawn, and the influence mechanisms of the four process parameters on polishing temperature are explored. Based on the relationship between the radius increment and compression depth of abrasive cloth wheel, flexible polishing and rigid polishing are defined, and the effects of flexible and rigid polishing on polishing temperature are explored. A main effect analysis of process parameters is conducted with polishing temperature as the response and process parameters as the factors, to study the degree of influence of each process parameter on polishing temperature. Results Comparing the measurement results, calculation results, and simulation results of polishing temperature, it is found that the deviation rates between the simulation values and the measurement values are less than 22%, and the devia-tion rates between the calculated values and the measurement values are less than 17%. The deviations between simu-lated values and measured values are mainly due to the actual heat source model being complex, while the simulated heat source model uses a simplified rectangular heat source model, as well as measurement errors. The deviations between calculated and measured values are mainly caused by measurement errors in contact arc length, temperature, heat distribution coefficient, and the heat source model. The influence of four process parameters on polishing temperature is as follows: polishing temperature increases with the increase of spindle speed, because higher spindle speed results in greater linear velocity of the abrasive cloth wheel, and more work is done by the frictional force between the abrasive particles, binder, and workpiece per unit time, generating more heat and resulting in higher polishing temperature; polishing temperature increases with the increase of the compression depth of the abrasive cloth wheel. This is because larger compression depth leads to greater tangential force on a single abrasive particle, and more abrasive particles participate in cutting. More work is done by the frictional force between the abrasive particles, binder, and workpiece per unit time, generating more heat, and resulting in higher polishing temperature; polishing temperature decreases with the increase of feed rate. Although higher feed rate enhances heat source intensity, the contact time between the workpiece and the heat source is shorter, resulting in less heat transferred to the workpiece and lower polishing temperature; polishing temperature decreases with the increase of mesh number of abrasive particles. This is because a larger mesh number of abrasive particle means smaller abrasive particle size and more abrasive particles interacting with the workpiece in the contact area, making heat more easily carried away by the abrasive particles. At the same time, the larger the mesh number of abrasive particle, the smaller the abrasive particle size, the larger the contact area between the workpiece and grinding tool, the smaller the tangential force exerted on a single abrasive particle, and the less work done by frictional force between the abrasive particle and the workpiece per unit time, generating less heat. These two reasons together lead to a decrease in polishing temperature with the increase of mesh number of abrasive particles. A main effect analysis shows that compression depth has the largest main effect and the greatest influence on polishing temperature, while the other three process parameters have smaller main effects and less influence on polishing temperature. Conclusions The value of compression depth has the greatest influence on the polishing temperature and also affects whether the polishing state is rigid or flexible. Therefore, when determining the polishing process parameters, the appropriate compression depth should be selected first, and then other process parameters should be selected accordingly.
- abrasive cloth wheel /
- polishing temperature /
- theoretical model

HTML全文

图 1 百叶轮实物图

Figure 1. Physical picture of abrasive cloth wheels

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图 2 百叶轮柔性抛光原理

Figure 2. Principle of flexible polishing with abrasive cloth wheel

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图 3 抛光力和抛光温度测量原理

Figure 3. Principle of measuring polishing force and polishing temperature

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图 4 现场试验图

Figure 4. Field test

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图 5 热成像图片

Figure 5. Thermal image

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图 6 矩形热源移动模型

Figure 6. Moving rectangular heat source model

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图 7 抛光过程

Figure 7. Polishing process

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图 8 抛光力信号

Figure 8. Polishing force signal

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图 9 抛光温度仿真流程

Figure 9. Polishing temperature simulation process

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图 10 ANSYS仿真的磨削表面温度场

Figure 10. Simulated results of grinding surface temperature field by ANSYS

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图 11 表面温度随位置变化曲线

Figure 11. Variation curve of surface temperature with position

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图 12 温度的计算值、仿真值和测量值对比

Figure 12. Comparison for calculated, simulated, and measured values of temperature

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图 13 工艺参数对抛光温度的影响规律

Figure 13. Influence law of process parameters on polishing temperature

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图 14 主效应分析

Figure 14. Main effect analysis

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表 1 特殊函数i(p,ξ)的值

Table 1. Values of special function i(p,ξ)

p	i(p,1)(p < 0)	p	i(p,1)(p > 0)
−0.05	0.199	0.05	0.189
−0.10	0.343	0.10	0.300
−0.20	0.576	0.20	0.472
−0.30	0.777	0.30	0.595
−0.40	0.955	0.40	0.683
−0.50	1.113	0.50	0.748
−0.60	1.252	0.60	0.749
−0.70	1.381	0.80	0.857
−0.80	1.504	1.00	0.896
−0.90	1.624	1.20	0.914
−1.00	1.739	1.40	0.932
−1.20	1.957	1.60	0.944
−1.40	2.160	1.80	0.947
−1.60	2.347	2.00	0.955
−1.80	2.528	2.20	0.958
−2.00	2.703	2.40	0.960
−2.20	2.871	2.60	0.961
−2.40	3.032	2.80	0.962
−2.60	3.188	3.00	0.962
−2.80	3.337	3.50	0.963
−3.00	3.481	4.00	0.963
−3.50	3.824	4.50	0.963
−4.00	4.154	5.00	0.963
−4.50	4.446	6.00	0.963
−5.00	4.749	7.00	0.963
−5.50	5.025	8.00	0.963
−6.00	5.290	9.00	0.963
−7.00	5.772
−8.00	6.231
−9.00	6.661
−10.0	7.068
−12.0	7.825
−14.0	8.523
−16.0	9.171
−18.0	9.780
−20.0	10.350
−22.0	10.910

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表 2 不同目数百叶轮对应的筛孔直径

Table 2. Sieve diameters corresponding to abrasive cloth wheels with different number of abrasive particles

百叶轮目数 P	筛孔直径 d / μm
240	61
320	44
400	38
600	23
1 000	13

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表 3 TC4在20 ℃时物理性能参数^[38]

Table 3. Physical performance parameters of TC4 at 20 ℃^[38]

性能参数	数值
密度 ρ / (kg·m⁻³)	4 450
比热容 c / (J·kg⁻¹·℃⁻¹)	612
热导率 λ / (W·m⁻¹·K⁻¹)	5.44

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表 4 E点温度的计算值、仿真值和测量值结果

Table 4. Calculation, simulation, and measurement results of temperature at point E

序号	主轴转速 n / (r·min⁻¹)	百叶轮压缩量 a_p / mm	进给速度 v_w / (mm·min⁻¹)	百叶轮磨粒目数 P	抛光力 F_t / N	测量值 θ_Em / ℃	仿真值 θ_Es / ℃	计算值 θ_Ec / ℃
1	4 000	1.2	200	180	6.38	44.87	45.22	46.76
2	8 000	1.2	200	180	11.78	53.45	49.96	51.48
3	6 000	0.8	200	180	1.90	37.66	40.89	42.39
4	6 000	1.6	200	180	55.39	96.36	78.55	82.78
5	6 000	1.2	100	180	7.27	51.71	49.47	47.67
6	6 000	1.2	300	180	12.46	35.72	38.12	36.55
7	6 000	1.2	200	120	30.55	56.95	50.64	52.83
8	6 000	1.2	200	320	8.83	44.22	45.15	46.74
9	6 000	1.2	200	180	9.46	49.85	49.25	50.61

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