CN113001266A - Online flexible finishing method of spherical micro-grinding tool based on electromagnetic rheological effect - Google Patents
Online flexible finishing method of spherical micro-grinding tool based on electromagnetic rheological effect Download PDFInfo
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- CN113001266A CN113001266A CN202110297069.5A CN202110297069A CN113001266A CN 113001266 A CN113001266 A CN 113001266A CN 202110297069 A CN202110297069 A CN 202110297069A CN 113001266 A CN113001266 A CN 113001266A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B1/00—Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes
- B24B1/005—Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes using a magnetic polishing agent
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B31/00—Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work and/or the abrasive material is loose; Accessories therefor
- B24B31/10—Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work and/or the abrasive material is loose; Accessories therefor involving other means for tumbling of work
- B24B31/112—Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work and/or the abrasive material is loose; Accessories therefor involving other means for tumbling of work using magnetically consolidated grinding powder, moved relatively to the workpiece under the influence of pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
- B24B49/006—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation taking regard of the speed
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B51/00—Arrangements for automatic control of a series of individual steps in grinding a workpiece
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B57/00—Devices for feeding, applying, grading or recovering grinding, polishing or lapping agents
- B24B57/02—Devices for feeding, applying, grading or recovering grinding, polishing or lapping agents for feeding of fluid, sprayed, pulverised, or liquefied grinding, polishing or lapping agents
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- Mechanical Engineering (AREA)
- Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
Abstract
The invention provides an online flexible trimming method of a spherical micro grinding tool based on an electromagnetic rheological effect, which utilizes the difference of the surface curvatures of the spherical micro grinding tool and a micro curved surface part to form a gradient pressure gap between the spherical micro grinding tool to be trimmed and the surface of the curved surface part, realizes the online trimming of the spherical micro grinding tool by controlling the distribution and the motion state of electromagnetic rheological nano particles in an electromagnetic rheological grinding fluid and under the synergistic action of the surface pressure of the micro curved surface part, and simultaneously realizes the surface pretreatment of the micro curved surface part. According to the invention, through online trimming/dressing of the spherical micro-grinding tool, the problems of serious micro-grinding tool loss and poor machining surface quality caused by small contact area of the spherical micro-grinding tool and the micro-curved surface part before machining of the micro-curved surface part can be solved, and repeated installation errors caused by offline trimming of the micro-grinding tool due to passivation can be avoided.
Description
Technical Field
The invention belongs to the technical field of trimming of micro-grinding tools in grinding processing, and particularly relates to an online flexible trimming method of a spherical micro-grinding tool based on an electromagnetic rheological effect.
Background
The micro grinding technology has the advantages of good precision, low cost, strong flexibility and the like, and can realize the processing of parts with tiny complex shapes/structures. However, the micro grinding tool applied to micro grinding processing has small size (<1mm), the manufacturing is very difficult, especially in the manufacturing process of the micro grinding tool, the distribution uniformity and the cutting height of the abrasive particles are difficult to ensure, and the micro grinding tool is difficult to accurately shape after being worn. In addition, the surface curvatures of the spherical micro grinding tool used for processing the micro curved surface part and the micro curved surface part are different, so that the spherical micro grinding tool and the surface of the micro curved surface part are always in point contact. In the initial stage of machining, the spherical micro-grinding tool usually only has a small amount of abrasive grains to participate in actual cutting machining, so that the loss of the abrasive grains is increased, and even the surface integrity of the micro-curved surface part is damaged. Therefore, it is important to perform the trimming/dressing of the micro-grinder before the micro-curved surface processing.
Researchers at home and abroad find that the electromagnetic rheological fluid is used as a novel intelligent material and can generate rheological effect under the action of an electromagnetic field, so that high-efficiency polishing and micro-removing of hard and brittle materials are realized, the electromagnetic rheological fluid is used as a controllable liquid and is not limited by a processing area and size, therefore, the electromagnetic rheological fluid is often used as a polishing medium to carry out local micro-polishing and micro-fine processing on micro curved surface parts so as to improve the surface shape precision of a micro optical element and the three-dimensional structure processing quality of a micro device, but the rheological fluid is directly used as a tool for processing, on one hand, the quantitative control on the electromagnetic rheological fluid is difficult, and only qualitative processing such as surface polishing can be carried out, on the other hand, the rheological fluid needs to be continuously replaced so as to keep the number of effective abrasive particles, and.
The publication number is CN205438026U, and discloses a technology for realizing automatic updating of grinding wheel fast abrasive and real-time repair of grinding wheel fast shape in the processing process by utilizing magneto-rheological effect, but the used grinding wheel is a common grinding wheel, the sizes of the grinding wheel and the grinding particles are large, the distribution and the motion characteristics of the magnetic abrasive particles in the grinding wheel and the grinding wheel are incapable of being accurately controlled due to the viscosity change characteristic of the magneto-rheological fluid, the magnetic line of force of a magnetic pole needs to be changed in a mode of rotating the magnetic pole, so that the sharpening of the grinding wheel is realized, and the grinding wheel is not suitable for the online dressing of a micro grinding tool with a small size.
Disclosure of Invention
The invention aims to solve the problems of high grinding tool loss and the like caused by small contact surface between a ball head micro grinding tool and a micro curved surface part. The method is economical, efficient, energy-saving and environment-friendly, and is suitable for the online flexible trimming method of the ball head micro-grinding tool, and can not only realize the online trimming/sharpening of the spherical micro-grinding tool according to the curvature of a micro-curved part, but also optimize the surface of the part.
In order to solve the technical problems, the invention adopts the following technical scheme: an online flexible finishing method of a spherical micro-grinding tool based on an electromagnetic rheological effect is characterized by comprising the following steps: the online flexible trimming method is realized by the following steps:
determining the components and proportion of the abrasive particles of the grinding fluid, the application mode and size of an electric/magnetic field and the dressing time according to the size of the spherical micro-grinding tool to be dressed, the granularity of the abrasive particles and the curvature of the curved surface of the micro-curved part; the method comprises the following steps of (1) filling electromagnetic rheological grinding fluid into a grinding fluid storage device, wherein the grinding fluid storage device is connected with a water pump and a flow control valve through pipelines, the flow of the fluid is controlled and adjusted through the flow control valve so as to realize quantitative and constant-speed output, and the electromagnetic rheological grinding fluid flows into an area between a spherical micro grinding tool and a micro curved surface part through the water pump and a nozzle;
the micro curved surface part is arranged in the center, the horizontal magnetic field auxiliary device is composed of 4 arc-shaped magnetic poles, the 4 arc-shaped magnetic poles are connected with the frequency conversion control unit through joints and independently controlled by 4 channels of the frequency conversion control unit to generate horizontal magnetic fields with different directions, sizes and action frequencies.
Under the action of a horizontal magnetic field with certain action frequency generated by 4 arc-shaped magnetic poles, the electromagnetic rheological nano particles in the electromagnetic rheological grinding fluid are horizontally spread and rotate around the center of the micro-grinder;
under the synergistic effect of the vertical magnetic field generated by the main axis coil and the vertical electric field generated by the power supply output current, the electromagnetic rheological grinding fluid is bonded and solidified, and other fine abrasive particles are bound between the chain structures.
When the spherical micro grinding tool rotates at a certain speed, abrasive particles in the electromagnetic rheological grinding fluid generate a micro cutting effect on the surfaces of the spherical micro grinding tool and the micro curved surface part under the combined action of the rotation motion of the micro grinding tool, a vertical electric field, a vertical magnetic field and a horizontal magnetic field, so that the surface finishing of the spherical micro grinding tool and the surface polishing or micro machining process of the micro curved surface part are realized.
Further, the spherical micro-grinding tool is a PCD spherical micro-grinding tool with a hard alloy matrix, the curvature radius of the surface of the micro-curved surface part is 5mm, the grinding fluid is prepared from 60% of silicone oil, 5% of suspending agent, 15% of titanium dioxide, 10% of ferroferric oxide nano particles and 10% of silicon dioxide powder, and the trimming gap is set to be 40 μm;
further, the spherical micro grinding tool, the micro curved surface part and the electric/magnetic field auxiliary generating device are arranged on a machine tool, and the initial gap between the spherical micro grinding tool and the micro curved surface part is adjusted to be 80 μm.
Further, the spherical micro-grinding tool is trimmed on line, the total trimming time is set to be 5 minutes, and the trimming is divided into rough trimming, fine trimming and light trimming, wherein:
rough trimming is carried out to obtain a lower electromagnetic field intensity and a lower spindle rotation speed, wherein the rotation speed range is larger than 2000rpm, and the time is 3 minutes;
fine modification is carried out for 1.5 minutes at a medium electromagnetic field intensity and a medium spindle rotating speed, wherein the rotating speed range is more than 6000 rpm;
the light modification is high electromagnetic field intensity, high main shaft rotating speed, rotating speed range larger than 12000rpm, and time of 0.5 minute.
Further, the direction of the horizontal magnetic field is controlled so that the movement direction of the abrasive grains in the grinding fluid is opposite to the rotation direction of the spindle.
Furthermore, the motion control of the electromagnetic composite particles is realized by adjusting the size and the direction of the magnetic field generated by the horizontal magnetic field auxiliary device.
Furthermore, the electromagnetic field generated by the vertical electric/magnetic field generating device is controlled to realize the formation of the electromagnetic composite particles into a chain structure and the electromagnetic composite particles are distributed in a vertical state.
Further, the dressing gap is 5 to 10 times the size of the abrasive grain of the spherical micro-grinder.
Furthermore, the abrasive size in the electromagnetic rheological grinding fluid is 10-50% of the abrasive size of the spherical micro-abrasive tool.
Further, the micro curved surface part is a concave micro curved surface part
Compared with the prior art, the invention has the following advantages and remarkable effects:
(1) the abrasive particles of the spherical micro-grinding tool can be sharpened, and the surface profile of the spherical micro-grinding tool can be adaptively trimmed according to the surface appearance of the micro-curved part, so that the area of a contact area between the spherical micro-grinding tool and the micro-curved part is increased, and the quality of a processed surface is improved. The online flexible forming and trimming device for the spherical micro grinding tool can control the distribution and the motion state of electromagnetic rheological nano particles in the electromagnetic rheological grinding fluid through the mutual matching of the generated horizontal magnetic field, the generated vertical electric field and the generated vertical magnetic field, and performs self-adaptive trimming on the surface of the spherical micro grinding tool under the synergistic action of the curved surface pressure of the micro part, so that the cutting height of abrasive particles on the surface of the spherical micro grinding tool is increased, the contact area between the spherical micro grinding tool and the surface of the micro curved surface part in the machining process is increased, and the machining surface quality and the service life of a cutter are improved.
(2) And special trimming equipment is not required to be added, and the error caused by repeated installation of the equipment in the traditional trimming method is avoided. The online flexible trimming device for the spherical micro-grinding tool based on the electromagnetic rheological effect completely performs trimming of the tool and optimization of the surface of the micro-curved part based on the interaction between the tool, the micro-curved part and the grinding fluid, does not need to introduce other special equipment, avoids repeated clamping of the tool or the micro-curved part due to the fact that the tool needs to be trimmed in the machining process, and greatly improves machining efficiency and machining precision.
(3) The pretreatment of the micro curved surface part can be realized, and the stability in the machining process is improved. When the micro-curved-surface part applies pressure to the spherical micro-grinding tool through the electromagnetic rheological grinding fluid, the surface of the micro-curved-surface part can be reversely optimized, so that the defects of local sharp corners, burrs and the like on the surface of the micro-curved-surface part can be removed in a micro-scale mode, the machining difficulty is reduced, and the stability in the machining process is improved.
Therefore, the spherical micro-grinding tool on-line flexible finishing method based on the electromagnetic rheological effect provided by the invention can be used for finishing the spherical micro-grinding tool, and can be used for overcoming the engineering technical problems of difficulty in finishing, high tool abrasion, low finishing efficiency, low finishing precision, poor controllability, poor application and the like of the conventional micro-grinding tool.
Drawings
FIG. 1 is a schematic view of an on-line flexible forming and finishing device for a spherical micro-abrasive tool;
FIG. 2 is a schematic diagram of an electric/magnetic field assisted generation device;
FIG. 3 is a schematic view of an arcuate magnetic pole;
FIG. 4 is a flow chart of an online flexible forming and finishing method of a spherical micro-abrasive tool;
FIG. 5 is a schematic view of a micro-removing of a spherical micro-abrasive tool and a micro-curved part;
wherein: 1-grinding fluid storage, 2-water pump, 3-flow control valve, 4-spindle, 5-spindle chuck, 6-spindle coil, 7-nozzle, 8-spherical micro grinding tool, 9-horizontal magnetic field auxiliary device, 10-frequency conversion control unit, 11-machine tool, 12-power supply, 13-oscilloscope, 14-micro curved surface part, 15-insulating plate, 16-electrode, 17-arc magnetic pole, 18-device frame, 19-arc iron core, 20-copper coil, 21-polymer partition plate and 22-electromagnetic rheological grinding fluid.
Detailed Description
The following detailed description of the embodiments of the present invention is provided in conjunction with the accompanying drawings of fig. 1-5.
As shown in fig. 1 to 3, this embodiment provides a nano-fluid electro-magneto-rheological grinding fluid and spherical micro-abrasive tool online flexible dressing device, which includes a grinding fluid storage 1, a water pump 2, a flow control valve 3, a main axis ring 6, a nozzle 7, a horizontal magnetic field auxiliary device 9, a frequency conversion control unit 10, a power supply 12, an oscilloscope 13, and an electrode 16, wherein: the grinding fluid storage device 1 is sequentially connected with the water pump 2, the flow control valve 3 and the nozzle 7 through pipelines, the flow rate and the flow speed of the liquid can be controlled and adjusted through the flow control valve 3, and the electromagnetic rheological grinding fluid 22 is output to the area between the spherical micro grinding tool 8 and the micro curved surface part 14 through the nozzle 7.
After the electro-magneto-rheological grinding fluid 22 is filled into the grinding fluid storage 1, the electro-magneto-rheological grinding fluid is input into the middle area between the spherical micro grinding tool 8 and the micro curved surface part 14 through the nozzle 7 under the action of the water pump 2, and under the action of a magnetic field generated by the horizontal magnetic field auxiliary device 9, the electro-magneto-rheological nano particles in the electro-magneto-rheological grinding fluid 22 are horizontally spread and rotate around the center of the spherical micro grinding tool 8.
The micro curved surface part 14 is fixed on a device frame 18 through an insulating plate 15 and an electrode 16, the insulating plate 15 separates the micro curved surface part 14 from the electrode 16, one sides of a power supply 12 and an oscilloscope 13 are connected with the electrode 16, one sides of the power supply 12 and the oscilloscope 13 are connected with a main shaft chuck 5 through an electric brush, and the power supply 12 is used for controlling the current output to generate a constant electric field in the vertical direction;
the spindle coil 6 is arranged around the periphery of the spindle chuck 5, connected with the variable frequency control unit 10 through wiring, and used for adjusting the action of a magnetic field by the variable frequency control unit 10, wherein the action of the magnetic field in the vertical direction is larger than that of a horizontal magnetic field;
the horizontal magnetic field auxiliary device 9 is arranged on a workbench of a machine tool 11 and comprises 4 arc-shaped magnetic poles 17, wherein the arc-shaped magnetic poles 17 are respectively provided with an arc-shaped iron core 19, a copper coil 20 and a polymer partition plate 21;
Under the synergistic effect of the vertical magnetic field generated by the spindle coil 6 and the vertical electric field generated by the output current of the power supply 12, the electromagnetic rheological grinding fluid 22 is subjected to viscosity change solidification, a large amount of electromagnetic rheological nanoparticles are gathered at the end of the micro grinding tool and form chain-shaped structures along the direction of an electromagnetic force line, other fine abrasive particles in the electromagnetic rheological grinding fluid 22 are bound between the chain-shaped structures, and as the vertical electromagnetic field intensity at the end of the spherical micro grinding tool 8 is the maximum, a large electromagnetic field gradient is formed by taking the end of the spherical micro grinding tool 8 as the center and is distributed radially.
When the spherical micro grinding tool 8 rotates at a certain speed, abrasive particles in the electromagnetic rheological grinding fluid 22 generate a micro-cutting effect on the surfaces of the spherical micro grinding tool 8 and the micro curved surface part 14 under the combined action of the rotation motion of the spherical micro grinding tool 8, a vertical electric field, a vertical magnetic field and a horizontal magnetic field, and meanwhile, because the curvature of the spherical micro grinding tool 8 is different from that of the micro curved surface part 14, the center removal amount of the spherical micro grinding tool 8 is the largest under the action of curved surface pressure and is gradually reduced outwards along the radial direction, so that the surface finishing of the spherical micro grinding tool 8 and the surface polishing or micro machining process of the micro curved surface part 14 are formed.
As shown in fig. 4 to 5, this embodiment further provides an online flexible trimming method for a spherical micro-abrasive tool based on electromagnetic rheological effect, which is implemented by the following steps:
determining the components and proportion of the abrasive particles of the needed electro-magneto-rheological grinding fluid 22, the application mode and size of an electric/magnetic field and the trimming time according to the size of the spherical micro-grinding tool 8 to be trimmed, the granularity of the abrasive particles and the curvature of the curved surface of the micro-curved-surface part 14; the method comprises the following steps of (1) filling electromagnetic rheological grinding fluid 22 into a grinding fluid storage device 1, wherein the grinding fluid storage device 1 is connected with a water pump 2 and a flow control valve 3 through pipelines, the flow of the liquid can be controlled and adjusted through the flow control valve 3 so as to realize quantitative and constant-speed output, and the electromagnetic rheological grinding fluid 22 flows into a region between a spherical micro grinding tool 8 and a micro curved surface part 14 through the water pump 2 and a nozzle 7;
in a preferred embodiment, the spherical micro-abrasive tool 8 is a PCD spherical micro-abrasive tool with a cemented carbide matrix, the diameter is d0.5mm, the abrasive grain size is 2500/3000#, the size is 5-5.5 μm, the curvature radius of the surface of the micro-curved part 14 is 5mm, and the specific modification method comprises the following steps: the composition of the electromagnetic rheological grinding fluid 22 is as follows: 60% of silicone oil, 5% of suspending agent and TiO 2215% of ferroferric oxide Fe3O410% of nano particles and silicon dioxide SiO 210% of the powder is prepared, and the trimming gap is set to be 40 mu m;
in a preferred embodiment, the spherical micro grinding tool 8, the micro curved surface part 14 and the electric/magnetic field auxiliary generating device are arranged on a machine tool, and the initial gap between the spherical micro grinding tool 8 and the micro curved surface part 14 is adjusted to be about 80 μm; then, preparing the electromagnetic rheological grinding fluid 22 according to the proportion, adding the electromagnetic rheological grinding fluid into the grinding fluid storage 1, and properly stirring to enable the grinding materials to be in a suspension state;
the spherical micro grinding tool 8 is arranged on the main shaft 4 through the main shaft clamp 5, and the connecting part of the main shaft clamp 5 and the main shaft 4 is coated with an insulating coating so as to ensure that current does not influence the main shaft.
The positive pole of the power source 12 is connected to the spindle chuck 5 through a carbon brush, and the negative pole is connected to an electrode 16 under the minute curved part 14 to generate a vertical electric field. The spindle coil 6 is installed around the periphery of the spindle chuck 5 and connected to the variable frequency control unit 100 through a joint to generate a vertical magnetic field. The oscilloscope 13 is connected with the power supply 12 to monitor the real-time change condition of the electric field.
The micro curved surface part 14 is arranged in the center, the horizontal magnetic field auxiliary device 9 is composed of 4 arc-shaped magnetic poles 17, the 4 arc-shaped magnetic poles 17 are connected with the frequency conversion control unit 10 through joints and independently controlled by 4 channels of the frequency conversion control unit 10 to generate horizontal magnetic fields with different directions, sizes and action frequencies. Under the action of a horizontal magnetic field with certain action frequency generated by the 4 arc-shaped magnetic poles 17, the electromagnetic rheological nano particles in the electromagnetic rheological grinding fluid 22 are horizontally spread and rotate around the center of the spherical micro grinding tool 8.
The 4 arc-shaped magnetic poles 17 can generate a continuously changing alternating magnetic field through pairwise alternate combination to realize the motion control of the electromagnetic rheological nanoparticles, so that the mobility of the electromagnetic rheological grinding fluid is enhanced.
In a preferred embodiment, an electric/magnetic field auxiliary generating device is used for generating a superposed electromagnetic field, and the motion state of the electromagnetic rheological nanoparticles in the electromagnetic rheological grinding fluid 22 is controlled, so that the spherical micro grinding tool 8 is subjected to online trimming, the total trimming time is set to be 5 minutes, and the trimming is divided into rough trimming, fine trimming and light trimming, wherein the rough trimming is performed by using a lower electromagnetic field strength and a lower main shaft rotating speed of 2,000-6,000rpm for 3 minutes, the fine trimming is performed by using a middle electromagnetic field strength, a middle main shaft rotating speed of 6,000-12,000rpm for 1.5 minutes, the light trimming is performed by using a high electromagnetic field strength, a higher main shaft rotating speed of 12,000-20,000rpm for 0.5 minutes;
in a preferred embodiment, the dressing gap may be selected to be 5-10 times the size of the abrasive grains of the spherical microabrasive tool 8.
In a preferred embodiment, the abrasive size in the rheomagnetic grinding fluid 22 can be selected to be between 10 and 50% of the abrasive size of the spherical superabrasive particles 8.
In a preferred embodiment, the spherical micro grinding tool 8 is trimmed, a small amount of electromagnetic rheological grinding fluid 22 is added into the middle area between the micro curved surface part 14 and the spherical micro grinding tool 8, the magnetic field directions of 4 arc-shaped magnetic poles of the horizontal magnetic field auxiliary device 9 are set to be the same and adjacent, the intervals are opposite, the horizontal magnetic field auxiliary device 9 is started, the output current of the variable frequency control unit 10 is gradually increased, so that the horizontal magnetic field is continuously enhanced, and meanwhile, the abrasive particles in the grinding fluid are observed to perform revolution motion around the spherical micro grinding tool 8;
wherein, the direction of the magnetic field is controlled to enable the motion direction of the abrasive particles in the electro-magneto-rheological grinding fluid 22 to be opposite to the rotation direction of the main shaft 4, thereby enhancing the dressing effect and dressing efficiency of the grinding tool.
Wherein, the vertical electric/magnetic field generating device is started, under the action of the vertical electromagnetic field, the abrasive particles in the electromagnetic rheological grinding fluid 22 are gathered towards the center of the spherical micro-grinding tool 8, and a chain structure is formed.
Wherein, the spherical micro grinding tool 8 is controlled to rotate, the initial rotating speed of the spherical micro grinding tool 8 is set to be 6,000rpm, and the finishing processing of the spherical micro grinding tool is completed according to the set finishing process flow.
And (4) carrying out finishing quality detection, namely observing the finishing condition of the surface of the micro grinding head by using a microscope after finishing one finishing so as to determine whether to stop or carry out the next finishing round again.
And stopping the machine after finishing the finishing, returning each part, powering off the electric/magnetic field auxiliary generating device, and performing the machining process of the micro curved surface part 14.
Under the synergistic effect of the vertical magnetic field generated by the main axis coil 6 and the vertical electric field generated by the power supply output current, the electromagnetic rheological grinding fluid 22 is subjected to viscosity change solidification, wherein a large amount of electromagnetic rheological nanoparticles are gathered at the end of the spherical micro grinding tool 8 and form chain-shaped structures along the direction of the vertical electromagnetic force line, other fine abrasive particles are bound among the chain-shaped structures, a large electromagnetic field gradient can be formed due to the maximum electromagnetic field intensity at the end of the spherical micro grinding tool 8, and the electromagnetic force lines are radially distributed by taking the end of the spherical micro grinding tool 8 as the center.
When the spherical micro-grinding tool 8 rotates at a certain speed, abrasive particles in the electromagnetic rheological grinding fluid 22 generate a micro-cutting effect on the surfaces of the spherical micro-grinding tool 8 and the micro-curved surface part 14 under the combined action of the rotation motion of the micro-grinding tool, the vertical electric field, the vertical magnetic field and the horizontal magnetic field, so that the surface finishing of the spherical micro-grinding tool 8 and the surface polishing or micro-machining process of the micro-curved surface part 14 are realized.
The curvature of the spherical micro grinding tool 8 is different from that of the micro curved surface part 14, the spherical micro grinding tool 8 rotates to drive surrounding liquid to rotate to generate fluid dynamic pressure, and under the dual action of curved surface pressure and electromagnetic force, a pressure gradient is formed between the spherical micro grinding tool 8 and the micro curved surface part 14 along the surface of the micro curved surface part 14 from the center of the spherical micro grinding tool 8 to the periphery, so that the spherical micro grinding tool 8 can be trimmed/sharpened at different degrees along the radial direction.
According to the comprehensive pressure distribution, the center of the spherical micro grinding tool 8 is removed in the largest amount and gradually decreases outwards along the radial direction. Finally, the increase of the processing contact area of the spherical micro grinding tool 8 and the micro curved surface part 14 is realized, and meanwhile, the contact motion of the abrasive particles in the electromagnetic rheological grinding fluid 22 and the surface of the micro curved surface part 14 can also promote the micro removal of the surface of the part, so that the curved surface polishing effect is achieved.
It is to be understood that this description of the invention is made only by way of example and not as a limitation to the application of the invention. The scope of the invention is defined by the appended claims and may include various modifications, alterations and equivalents of the patented invention without departing from the scope and spirit of the invention.
Claims (10)
1. An online flexible finishing method of a spherical micro-grinding tool based on an electromagnetic rheological effect is characterized by comprising the following steps: the online flexible trimming method is realized by the following steps:
determining the components and proportion of the abrasive particles of the needed electro-magneto-rheological grinding fluid (22), the application mode and size of an electric/magnetic field and the trimming time according to the size of the spherical micro-grinding tool (8) to be trimmed, the granularity of the abrasive particles and the curvature of the curved surface of the micro-curved surface part; the method comprises the following steps of (1) filling electromagnetic rheological grinding liquid (22) into a grinding liquid storage device (1), connecting the grinding liquid storage device (1) with a water pump (2) and a flow control valve (3) through pipelines, controlling and adjusting the liquid flow through the flow control valve (3) to realize quantitative and constant-speed output, and enabling the electromagnetic rheological grinding liquid (22) to flow into an area between a spherical micro grinding tool (8) and a micro curved surface part (14) through the water pump (2) through a nozzle;
the micro curved surface part (14) is arranged at the center, the horizontal magnetic field auxiliary device (9) is composed of 4 arc-shaped magnetic poles (17), the 4 arc-shaped magnetic poles (17) are connected with the frequency conversion control unit (10) through joints, and independent control is carried out by means of 4 channels of the frequency conversion control unit (10) so as to generate horizontal magnetic fields with different directions, sizes and action frequencies.
Under the action of a horizontal magnetic field with certain action frequency generated by 4 arc-shaped magnetic poles (17), electromagnetic rheological nanoparticles in the electromagnetic rheological grinding fluid (22) are horizontally spread and rotate around the center of the micro-grinder;
under the synergistic effect of a vertical magnetic field generated by the main axis coil (6) and a vertical electric field generated by the output current of the power supply (12), the electromagnetic rheological grinding fluid (22) is subjected to viscosity change solidification, electromagnetic rheological nanoparticles are gathered at the end part of the spherical micro grinding tool (8) in a large amount and form chain-shaped structures along the direction of a vertical electromagnetic line, other fine abrasive particles are bound between the chain-shaped structures, a large electromagnetic field gradient can be formed due to the fact that the electromagnetic field intensity at the end part of the spherical micro grinding tool (8) is the maximum, and the electromagnetic line is distributed radially by taking the end part of the spherical micro grinding tool (8) as the center.
When the spherical micro grinding tool (8) rotates at a certain speed, abrasive particles in the electromagnetic rheological grinding fluid (22) generate micro cutting action on the surfaces of the spherical micro grinding tool (8) and the micro curved surface part (14) under the combined action of the rotation motion of the micro grinding tool, a vertical electric field, a vertical magnetic field and a horizontal magnetic field, so that the surface finishing of the spherical micro grinding tool (8) and the surface polishing or micro machining process of the micro curved surface part (14) are realized.
2. The method for the online flexible finishing of the spherical micro-abrasive tool based on the electromagnetic rheological effect according to claim 1, characterized in that: the spherical micro-grinding tool (8) is a PCD spherical micro-grinding tool with a hard alloy matrix, the curvature radius of the surface of the micro-curved surface part (14) of the micro-curved surface part is 5mm, and the electromagnetic rheological grinding fluid (22) comprises 60% of silicone oil, 5% of suspending agent and titanium dioxide (TiO)2) 15% ferroferric oxide (Fe)3O4) 10% of nanoparticles and silicon dioxide (SiO)2) The powder was 10% configured and the dressing gap was set to 40 μm.
3. The method for the online flexible finishing of the spherical micro-abrasive tool based on the electromagnetic rheological effect according to claim 1, characterized in that: the spherical micro grinding tool (8), the micro curved surface part (14) and the electric/magnetic field auxiliary generating device are arranged on a machine tool, and the initial gap between the spherical micro grinding tool (8) and the micro curved surface part (14) is adjusted to be 80 mu m.
4. The method for the online flexible finishing of the spherical micro-abrasive tool based on the electromagnetic rheological effect according to claim 1, characterized in that: the spherical micro-grinding tool (8) is trimmed on line, the total trimming time is set to be 5 minutes, and the trimming is divided into rough trimming, fine trimming and light trimming, wherein:
rough trimming is carried out on the magnetic field of a lower electromagnetic field intensity and a lower spindle rotation speed, the rotation speed range is more than 2,000rpm and less than or equal to 6,000rpm, and the time is 3 minutes;
the fine modification is the medium electromagnetic field intensity and the medium main shaft rotating speed, the rotating speed range is more than 6,000rpm and less than or equal to 12,000rpm, and the time is 1.5 minutes;
the light modification is high electromagnetic field intensity, high main shaft rotating speed, the rotating speed range is more than 12,000 and less than or equal to 20,000rpm, and the time is 0.5 minute.
5. The method for the online flexible finishing of the spherical micro-abrasive tool based on the electromagnetic rheological effect according to claim 1, characterized in that: the direction of the horizontal magnetic field is controlled to enable the movement direction of abrasive particles in the electro-magneto-rheological grinding fluid (22) to be opposite to the rotation direction of the main shaft (4).
6. The method for the online flexible finishing of the spherical micro-abrasive tool based on the electromagnetic rheological effect according to claim 1, characterized in that: the motion control of the electromagnetic composite particles is realized by adjusting the size and the direction of the magnetic field generated by the horizontal magnetic field auxiliary device (9).
7. The method for the online flexible finishing of the spherical micro-abrasive tool based on the electromagnetic rheological effect according to claim 1, characterized in that: the electromagnetic field generated by the vertical electric/magnetic field generating device is controlled to realize the formation of the electromagnetic composite particles into a chain structure and the electromagnetic composite particles are distributed in a vertical state.
8. The method for the online flexible finishing of the spherical micro-abrasive tool based on the electromagnetic rheological effect according to claim 1, characterized in that: the dressing gap is 5-10 times of the size of the abrasive grains of the spherical micro-grinder.
9. The method for the online flexible finishing of the spherical micro-abrasive tool based on the electromagnetic rheological effect according to claim 1, characterized in that: the size of the abrasive in the electro-magneto-rheological grinding fluid (22) is 10-50% of that of the abrasive of the spherical micro-grinding tool (8).
10. The method for the online flexible finishing of the spherical micro-abrasive tool based on the electromagnetic rheological effect according to claim 1, characterized in that: the micro curved surface part (14) is a concave micro curved surface part.
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