Study on Multi-objective Optimization of Processing Parameters in Curved Surface Grinding and Polishing of Elastic Abrasive
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摘要: 硬质合金曲面工件磨抛加工时，影响因素较多且存在耦合，磨抛效率低且质量不稳定。为在工件表面实现高效磨抛，同时降低磨具磨损，以M300钢为研究对象，通过分析其与弹性磨具的接触区域特征来建立曲面磨抛的材料去除函数模型，并通过实验验证模型的可靠性。通过单因素实验方法研究磨具的转速、切入深度、进给速度、粒度工艺参数对材料去除率、磨具磨损和工件表面粗糙度的影响规律。利用正交实验和灵敏度分析法确定各个评价目标的优化参数组合和多目标的优化参数区间。实验结果表明，利用该优化参数区间，工件表面质量有所改善，磨具磨损有所减轻。Abstract: When the workpiece of cemented carbide surface is grinded and polished, there are many influencing factors and coupling, and the grinding and polishing efficiency is low and the quality is unstable. In order to achieve high-efficiency grinding and polishing on the surface of the workpiece and reduce the wear of the abrasive tool, the characteristics of the contact area between M300 steel and the elastic abrasive tool was analyzed in order to establish the removal function model for the surface grinding and polishing material; the reliability of the model was also verified by the experimental results. The effects of the grinding tool rotation speed, penetration depth, feed rate and abrasive particle size on the material removal rate, abrasive wear and workpiece surface roughness were studied by the single factor experiment, in which the orthogonal experiment and sensitivity analysis method were used to determine the optimal parameter combination and the multi-objective optimization parameter interval of each evaluation target. The experimental results showed that the surface quality of the workpiece was improved and the wear of the abrasive tool was reduced by using the optimized parameter interval.
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表 1 磨抛参数选用
名称 内容 弹性磨具 结合剂:硅橡胶, R1=10 mm, H1=45~95 kg/mm2 磨粒 材料:碳化硅, 粒度S:320#, E1=4.06×105 MPa, Ht=3 000 kg/mm2 试件 M300钢圆柱件, R2=20 mm, E2=2.06×105 MPa, H2=60 kg/mm2 其它 Wt=Vs/R1=3 000~9 000 r/min, Vf=1 mm/min, ap=0.1~0.5 mm 
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表 2 磨抛实验参数
参数名称 参数数值 磨粒粒度S 320#、600#、1 000# 加工时间T 60~360 s 磨具转速wt 1 500~12 000 r/min 进给速度vf 0.5~4 mm/min 切入深度ap 0.1~0.5 mm
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表 3 正交实验表
加工参数 水平 1 2 3 磨具粒度S 320# 600# 1 000# 磨具转速wt/(r·min-1) 4 500 6 000 7 500 切入深度ap/mm 0.1 0.2 0.4 进给速度vf/(mm·min-1) 0.5 1 2 单位加工时间T/s 180 - - 加工循环次数 3 - -
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表 4 实验结果表
No 加工参数 实验数据 S wt ap vf MRR/(mm3·min-1) Zw Ra/μm 1 1 1 1 1 0.063 0.1 0.086 2 2 2 3 1 0.278 0.08 0.116 3 3 3 2 1 0.291 0.13 0.162 4 2 3 1 2 0.177 0.12 0.089 5 1 2 2 2 0.949 0.39 0.134 6 3 1 3 2 0.189 0.37 0.078 7 3 2 1 3 0.139 0.08 0.132 8 2 1 2 3 0.266 0.11 0.104 9 1 3 3 3 2.152 0.52 0.105
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表 5 各参数水平对材料去除率的信噪比(SNR)
加工参数 S wt ap vf 水平 1 8.333 1.367 1.000 1.667 2 1.900 3.600 3.967 3.467 3 6.700 5.533 5.900 5.067
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表 6 各参数水平对磨耗比的信噪比(SNR)
加工参数 S wt ap vf 水平 1 -11.34 -15.94 -20.37 -20.27 2 -20.48 -17.74 -15.02 -11.99 3 -16.1 -14.25 -12.53 -15.65
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表 7 各参数水平对表面粗糙度的信噪比(SNR)
加工参数 S wt ap vf 水平 1 19.448 0 21.802 1 19.981 1 18.635 3 2 19.851 9 17.922 3 17.642 3 21.001 7 3 19.256 5 18.832 1 20.933 1 18.919 5
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表 8 磨抛工艺参数优化区间
磨抛工艺参数 优化区间 稳定性 表面粗糙度变化趋势 S [300,600] 非稳定 0.102~0.108 wt/(r·min-1) [4 500, 7 500] 稳定 0.083~0.118 ap/mm [0.1, 0.3] 非稳定 0.093~0.102 vf/(mm·min-1) [0.5, 2] 非稳定 0.094~0.121
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表 9 参数区间优化实验结果
参数组合 加工参数 实验数据 S wt/(r·min-1) ap/mm vf/(mm·min-1) MRR/(mm3·min-1) Zw Ra/μm min Ra 600# 4 500 0.4 1 0.127 0.12 0.073 min Zw 600# 6 000 0.1 0.5 0.136 0.44 0.115 优化区间 320# 4 500 0.3 1 0.760 0.28 0.063
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