磁弹磨粒双磁盘磁力钝化仿真与实验研究

doi:10.12141/j.issn.1000-565X.220404

摘要/Abstract

摘要：

磁弹磨粒具有磁性、低弹性模量以及优良的研磨性能，能够提高加工效率和加工质量。首先，基于磁场基本理论和磁弹磨粒特性，分析了磁弹磨粒双磁盘磁力刀具钝化机制；然后，基于磁场中磁弹磨粒的磁场力对离散元软件EDEM进行二次开发，建立了磁弹磨粒双磁盘磁力刀具钝化过程仿真模型，研究了磨粒粒度、磁化率和磁盘间距对刃口碰撞次数和磨粒旋转速度的影响规律；最后，采用Matlab软件对刀具刃口轮廓进行重建，提出了基于钝化面积的改进形状因子表征方法，通过正交实验研究了磨粒粒度、磁化率和磁盘间距对刃口钝化量的影响规律，并验证了所提改进形状因子表征方法的可行性。结果表明：随着磁弹磨粒粒度的增大、磁化率的增加和磁盘间距的减小，刃口碰撞次数和磨粒旋转速度增大；钝化参数对刃口钝化量的影响程度大小依次为磨粒粒度、磁盘间距、磁化率，最优钝化参数组合为磨粒粒度40目、磁化率0.1、磁盘间距15 mm；仿真与实验钝化面积的最大相对误差为16.33%，最小相对误差为0.42%，仿真能够较好地预测刃口钝化形貌，且改进的刃口形状因子能够较好地表征刀具刃口钝化形貌。

关键词: 磁弹磨粒, 刀具, 磁力钝化, EDEM二次开发, 改进形状因子

Abstract:

Magneto-elastic abrasive is magnetic and has low elastic modulus as well as excellent grinding performance. It can improve the quality and efficiency of process. Firstly, the magnetic edge preparation mechanism was analyzed based on the theory of magnetic field and magneto-elastic abrasive characteristics. Secondly, secondary development for discrete element software EDEM was carried out based on magnetic force of magneto-elastic abrasive in magnetic field, and a simulation model of dual-disk magnetic edge preparation process was established. The effects of particle size, magnetic susceptibility and disk spacing on the number of edge collisions and abrasive rotation velocity were studied. Finally, Matlab software was used to reconstruct the edge contour and an improved shape factor characterization method based on preparation area was proposed. The influence of particle size, magnetic susceptibility and disk spacing on edge preparation value was studied by orthogonal experiment, and the feasibility of proposed improved shape factor characterization was verified. The results show that, the number of edge collisions and the rotation speed of abrasive increase with the increase of particle size, the increase of magnetic susceptibility and the decrease of disk spacing. In addition, the degree of influence of preparation parameters on the preparation amount of the cutting edge in descending order is particle size, disk spacing and magnetic susceptibility, and the optimal preparation parameter groups are particle size 40 mesh, magnetic susceptibility 0.1, and disk spacing 15 mm. The maximum relative error of preparation area between simulation and experiment is 16.33% and the minimum relative error is 0.42%. Simulation can better predict preparation morphology of the cutting edge, and the improved edge shape factor can better characterize the preparation morphology of the cutting edge.

Key words: magneto-elastic abrasive, cutting tools, magnetic preparation, EDEM secondary development, improved shape factor

中图分类号:

TG71

赵雪峰, 游科, 袁银, 等. 磁弹磨粒双磁盘磁力钝化仿真与实验研究[J]. 华南理工大学学报(自然科学版), 2023, 51(5): 130-140.

ZHAO Xuefeng, YOU Ke, YUAN Yin, et al. Simulation and Experimental Research on Dual-Disk Magnetic Preparation Based on Magneto-Elastic Abrasive[J]. Journal of South China University of Technology(Natural Science Edition), 2023, 51(5): 130-140.

图/表 22

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图16

表1

图17

表2

图18

图19

表3

仿真与实验钝化面积比较"

实验编号	仿真钝化面积/μm²			实验钝化面积/μm²			相对误差/%
实验编号	$Δ S γ$	$Δ S α$	$Δ S$	$Δ S γ$	$Δ S α$	$Δ S$	相对误差/%
1	28.69	28.66	57.35	31.27	32.33	63.60	9.83
2	40.37	40.40	80.77	35.86	39.84	75.69	6.71
3	17.76	17.74	35.50	17.50	17.51	35.01	1.40
4	9.67	9.65	19.32	9.62	9.62	19.24	0.42
5	17.94	17.91	35.85	17.20	17.00	34.21	4.79
6	29.92	29.90	59.82	29.29	30.28	59.57	0.42
7	5.68	4.62	10.30	7.10	5.21	12.31	16.33
8	7.32	6.72	14.04	8.62	7.28	15.90	11.70
9	4.80	4.59	9.39	4.58	4.27	8.85	6.10

表3

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水平	磨粒粒度	磁化率	磁盘间距
极差	0.372	0.053	0.219
k₁	0.972	0.736	0.841
k₂	0.728	0.775	0.836
k₃	0.600	0.789	0.622

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