基于相位调控的二维超声辅助砂带磨削方法及其对GH4169表面完整性研究

doi:10.3901/JME.2024.21.349

机械工程学报 ›› 2024, Vol. 60 ›› Issue (21): 349-364.doi: 10.3901/JME.2024.21.349

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基于相位调控的二维超声辅助砂带磨削方法及其对GH4169表面完整性研究

李少川^1,2, 肖贵坚^2,3, 曹华军^2,3, 汪迎新², 赵泽勇², 卓晓琴², 黄云^2,3

1. 郑州轻工业大学机电工程学院郑州 450002;
2. 重庆大学机械与运载工程学院重庆 400044;
3. 高端装备机械传动全国重点实验室重庆 400044

收稿日期:2023-12-08 修回日期:2024-05-11 发布日期:2024-12-24
通讯作者: 肖贵坚，男，1986年出生，博士，副教授，博士研究生导师。主要研究方向为多能场协同材料去除、微纳结构激光砂带协同加工、超声辅助加工表面及其服役性能、复杂曲面加工编程及机器人控制、高服役加工参数优化与智能决策。E-mail：xiaoguijian@cqu.edu.cn
作者简介:李少川,男,1993年出生,博士,讲师。主要研究方向为超声辅助加工、抗疲劳表面加工以及砂带磨削。E-mail:lishaochuanCQU@163.com;曹华军,男,1978年出生,博士,教授,博士研究生导师。主要研究方向为绿色制造、高速干切工艺与装备。E-mail:hjcao@cqu.edu.cn;黄云,男,1962年出生,博士,教授,博士研究生导师。主要研究方向为超精密加工理论与技术;智能制造装备;抗疲劳制造技术。E-mail:hjcao@cqu.edu.cn
基金资助:
国家重点研发计划(2020YFB2010500)、山东省科技型中小企业创新能力提升工程(2022TSGC1115)和山东省自然科学基金(ZR2023QE057，ZR2022QE028，ZR2021QE116，ZR2020KE027)资助项目。

Two-dimensional Ultrasound-assisted Belt Grinding Method Based on Phase Regulation and its Effect on the Surface Integrity of GH4169

LI Shaochuan^1,2, XIAO Guijian^2,3, CAO Huajun^2,3, WANG Yingxin², ZHAO Zeyong², ZHUO Xiaoqin², HUANG Yun^2,3

1. College of Mechanical and Electrical Engineering, Zhengzhou University of Light Industry, Zhengzhou 450002;
2. College of Mechanical and Vehicle Engineering, Chongqing University, Chongqing 400044;
3. State Key Laboratory of Mechanical Transmissions, Chongqing 400044

Received:2023-12-08 Revised:2024-05-11 Published:2024-12-24

摘要/Abstract

摘要： 镍基高温合金加工过程易产生表面损伤，且服役性能对表面纹理和缺陷具有强相关性。同时，复杂载荷状态对构件表面提出了各向同性加工需求。融合砂带磨削柔性、低损伤特点和超声辅助加工纹理优化优势，提出了二维超声辅助砂带磨削方法。分析了不同工艺参数下磨粒运动轨迹，基于单颗粒划擦试验分析了超声方向、振幅和相位对材料去除行为的影响，并揭示了工艺参数对GH4169表面完整性及其均匀性的影响规律。结果表明：二维超声辅助砂带磨削具有较好的纹理优化效果，同时可以获得均匀塑性变形层。通过相位调控可以制备出类网状纹理，抑制了表面完整性各向异性。相位差90°时表面完整性及分布一致性较好，其中较大振幅可以提升表面残余压应力、降低表面粗糙度。纹理优化和材料去除之间存在竞争机制，较低进给速度可以获得较小表面粗糙度和较大残余压应力。

关键词: 超声辅助磨削, 平面二维超声振动, 砂带磨削, 表面完整性, 各向异性, GH4169

Abstract: Nickel-based superalloys are prone to surface damage during machining, and its service performance has strong correlation with surface texture and defects. Meanwhile, complex load puts forward isotropic processing requirements. Combining flexible and low damage of belt grinding and texture optimization of ultrasonic-assisted machining, two-dimensional ultrasonic-assisted belt grinding method is proposed. The abrasive trajectory under different parameters is analyzed, and the influence of ultrasonic direction, amplitude and phase on material removal is analyzed based on single-particle scratch test. The influence of process parameters on surface integrity and uniformity of GH4169 is also revealed. Results show that two-dimensional ultrasonic-assisted belt grinding has texture optimization effect, and can obtain uniform plastic deformation layer. Reticulum-like texture can be prepared and the anisotropy of surface integrity can be suppressed. Phase difference of 90°improves surface integrity and consistency. Large amplitude can increase residual compressive stress and reduce surface roughness. Low feed speed result in small roughness and large residual compressive stress.

Key words: ultrasonic assisted grinding, planar two-dimensional ultrasonic vibration, abrasive belt grinding, surface integrity, anisotropy, GH4169

中图分类号:

TG156

李少川, 肖贵坚, 曹华军, 汪迎新, 赵泽勇, 卓晓琴, 黄云. 基于相位调控的二维超声辅助砂带磨削方法及其对GH4169表面完整性研究[J]. 机械工程学报, 2024, 60(21): 349-364.

LI Shaochuan, XIAO Guijian, CAO Huajun, WANG Yingxin, ZHAO Zeyong, ZHUO Xiaoqin, HUANG Yun. Two-dimensional Ultrasound-assisted Belt Grinding Method Based on Phase Regulation and its Effect on the Surface Integrity of GH4169[J]. Journal of Mechanical Engineering, 2024, 60(21): 349-364.

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基于相位调控的二维超声辅助砂带磨削方法及其对GH4169表面完整性研究

Two-dimensional Ultrasound-assisted Belt Grinding Method Based on Phase Regulation and its Effect on the Surface Integrity of GH4169

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