Surface integrity and chip formation in abrasive flow machining
Surface integrity and chip formation in abrasive flow machining
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磨料流加工中的表面完整性和切屑形成
DOI：
10.1016/j.procir.2018.05.048
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发表时间：
--
期刊：
影响因子：
--
通讯作者：
Roßkamp
中科院分区：
文献类型：
--
作者：
Uhlmann E;Roßkamp
由于要求的不断提高，工件变得更加复杂。在生产几何图形的加工操作之后，表面粗糙度、去毛刺和边缘圆化的要求通常不能满足。这导致了必要的整理工艺。对于这些内部轮廓的挑战，一个广泛使用的解决方案是磨料流加工。用于减少钢制零件甚至难加工材料的表面粗糙度、去毛刺和边缘圆整。结果表明，表面粗糙度可降至Ra=0.04µm，去毛刺率、边缘圆整率和边缘形状可根据加工参数的适当选择进行调整，除了表面粗糙度和边缘圆整度的结果外，还有更多表征表面完整性的参数。为了达到这些目的，还可以给出残余应力、显微硬度和金属组织变化的值。为了便于工业应用，对几何形状、加工时间、活塞行程长度和流量等加工参数的表面完整性进行了研究。给出了表面粗糙度、边缘圆度(包括边缘形状和残余应力)的计算结果。在可热处理钢和大批量生产的磨料流加工介质的加工过程中，对所有这些量进行了检验。此外，本文还提出了一种新的方法来证明现有的切屑形成理论。由于关于表面完整性的新发现，有可能得出关于切屑形成点的物理过程的结论。从长远来看，这些结论可以用于摩擦模型，这将是全面过程模型的一部分。在此工艺模型的基础上，可以进行工艺模拟，以减少工艺设计所需的时间，提高工艺设计的质量。
Due to rising requirements workpieces become more complex. After machining operations in which the geometry is produced, the claims of surface roughness, deburring and edge rounding aren’t often satisfied. This leads to necessary finishing processes. A widely used solution for those challenges on inner contours is abrasive flow machining. It is used for reducing surface roughness, deburring and edge rounding in workpieces made of steel and even difficult to machine materials. As result the surface roughness can be decreased down to Ra = 0.04 µm. The rate of deburring, edge rounding and edges’ shapes can be adjusted in correlation to a suitable choice of machining parameters.Besides results of surface roughness and edge rounding there are many more parameters for characterizing the surface integrity. For these purposes values of residual stress, micro hardness and changes in metallic structure could be given, too. To make the investigations useful for industrial applications, surface integrity is researched for several processing parameters like geometry, process time, piston stroke length and flow rate. Presented results are surface roughness, edge rounding including edges’ shape and residual stress. All these quantities are examined in machining processes with heat treatable steel and a media for abrasive flow machining in mass production.Moreover, a new approach of proving the existing theory of chip formation is presented in this paper. Due to the new findings about the surface integrity, it is possible to draw conclusions referring the physical processes at the point of chip formation. In the long run, these conclusions can be used for a friction model, which will be part of a comprehensive process model. On the basis of this process model a process simulation will be possible, which can be used to reduce the required time of process design and to increase the quality of process design.
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