Process Parameter Optimization of Outer Ring Raceway in ELID Forming Grinding of Ball Bearings
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摘要: 为了优化球轴承外圈沟道ELID(Electrolytic In-process Dressing) 成形磨削工艺参数,通过多因素正交试验研究了ELID成形磨削过程中磨削参数和电解参数对砂轮磨损和工件表面粗糙度的影响规律,综合砂轮径向磨损量和工件表面粗糙度两个指标对磨削试验进行了综合评估。结果表明,磨削参数中的径向进给速度对砂轮径向磨损量的影响最大,砂轮转速对工件表面粗糙度影响最大;电解参数中的占空比对砂轮径向磨损量的影响较大,电解电压对工件表面粗糙度影响较大;砂轮转速为18 000 r/min,工件转速为100 r/min,径向进给速度为1 μm/min,占空比为50%,电解电压为90 V(6.7 Ω)时,综合效果最优。Abstract: In order to optimize the process parameters of the outer ring raceway in the ELID forming grinding of ball bearings, the effects of the grinding parameters and electrolytic parameters on the grinding wheel wear and workpiece surface roughness in the ELID forming grinding process were studied by multi factor orthogonal test. And the grinding was evaluated by two indexes of grinding wheel radial wear and workpiece surface roughness. The results showed that the radial feed speed of grinding parameters has the greatest influence on the radial wear of grinding wheel, and the wheel rotation speed has the greatest influence on the surface roughness of workpiece; the duty ratio of electrolytic parameters has a greater influence on the radial wear of grinding wheel, and the electrolytic voltage has a greater influence on the surface roughness of workpiece; the grinding effect is the best at a grinding wheel rotation speed of 18 000 r/min, workpiece rotation speed of 100 r/min, radial feed speed of 1 μm/min, duty cycle of 50%, and an electrolytic voltage of 90 V(6.7 Ω).
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Key words:
- ELID forming grinding /
- outer ring raceway /
- wheel wear /
- surface roughness /
- optimal process parameters
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表 1 试验设备及条件
设备、条件 型号、参数 电极方式 工件阴极 磨床 3MZ1 410(数控升级) 电源 高频直流脉冲电源(TJCP-Ⅱ) 磨削液 ELID专用磨削液(TJMX-V) 砂轮 W40铸铁基CBN砂轮, 磨粒尺寸为28~40 μm, 浓度为100% 工件 6 206球轴承外圈 粗糙度仪 FormTalysurfi120泰勒粗糙度仪 MDS-50电阻应变式微型力传感器 灵敏度>1.743 7 mV/V, 线性误差<2%F.S, 重复性误差<6%F.S, 激励电压5-12VDC; 动态电阻应变仪 增益1 000, 电源8 V, 量程2 V 表 2 试验工艺参数范围
工艺参数 取值范围 砂轮转速/(r·min-1) 12 000~18 000 工件转速/(r·min-1) 100~400 径向进给速度/(μm·min-1) 1~4 电源电压/V 60~120 占空比/% 20~100 表 3 因素水平表
参数名 水平 1 2 3 4 砂轮转速/(r·min-1) 12 000 14 000 16 000 18 000 工件转速/(r·min-1) 100 200 300 400 径向进给速度/(μm·min-1) 1 2 3 4 占空比/% 25 50 75 100 电解电压 60 V (6.7Ω) 60 V (20Ω) 90 V (6.7Ω) 90 V (20Ω) 表 4 球轴承外圈沟道ELID成形磨削试验设计表
试验序号 砂轮转速/ (r·min-1) 工件转速/ (r·min-1) 径向进给速度/(μm·min-1) 占空比/% 电解电压 1 12 000 100 1 25 60V(6.7Ω) 2 12 000 200 2 50 60V(20Ω) 3 12 000 300 3 75 90V(6.7Ω) 4 12 000 400 4 100 90V(20Ω) 5 14 000 100 2 75 90V(20Ω) 6 14 000 200 1 100 90V(6.7Ω) 7 14 000 300 4 25 60V(20Ω) 8 14 000 400 3 50 60V(6.7Ω) 9 16 000 100 3 100 60V(20Ω) 10 16 000 200 1 75 60V(6.7Ω) 11 16 000 300 4 50 90V(20Ω) 12 16 000 400 2 25 90V(6.7Ω) 13 18 000 100 4 50 90V(6.7Ω) 14 18 000 200 3 25 90V(20Ω) 15 18 000 300 2 100 60V(6.7Ω) 16 18 000 400 1 75 60V(20Ω) 表 5 球轴承外圈沟道ELID成形磨削试验结果
试验序号 工件表面粗糙度Ra/μm 砂轮径向磨损量W/μm 1 1.04 2.4 2 1.04 3.2 3 0.96 10.1 4 0.95 11.8 5 0.86 2.5 6 0.85 7.3 7 1.05 6.5 8 0.94 8.8 9 0.96 8.5 10 0.91 7.8 11 0.85 3.5 12 0.89 4.5 13 0.82 7.1 14 0.90 5.2 15 0.85 7.3 16 0.96 4.5 表 6 各工艺参数对两个指标的综合均值响应
μm 因素 砂轮转速 工件转速 径向进给速度 占空比 电解电压 水平1 0.713 0.406 0.483 0.570 0.489 水平2 0.448 0.439 0.355 0.391 0.704 水平3 0.365 0.469 0.540 0.438 0.312 水平4 0.295 0.506 0.442 0.422 0.315 极差 0.418 0.100 0.185 0.179 0.392 影响程度 砂轮转速>电解电压>径向进给速度>占空比>工件转速 表 7 最优工艺参数
砂轮转速/ (r·min-1) 工件转速/ (r·min-1) 径向进给速度/ (μm·min-1) 占空比/% 电解电压 18 000 100 1 50 90 V (6.7 Ω) -
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