外文翻译--运用磨削中心弹性砂轮的一种曲面高效抛光技术.doc
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外文翻译--运用磨削中心弹性砂轮的一种曲面高效抛光技术.doc
外文资料HighProductiveTechniqueforPolishingFreeSurfacewithElasticBallTypeWheelonGrindingCenterPolishingisanimportantfinishingprocessindieandmoldmanufacturing.Handpolishingtakeslongtimeandmuchlabor.Effortsaremadetoautomatethepolishingprocesswhilekeepingaccuracy.Recentlygrindingcentershavebeendeveloped,whichareusedforfreesurfacepolishinginthepresentwork.Thenewpolishingtechniqueappliesthesamecuttinglocusasusedinthecuttingprocesstoremoveonlycuspheighteffectively,keepingtheformaccuracygeneratedinthecuttingprocess.1IntroductionDieandmoldconstructedwithvariousfreesurfacesareimportantinmanufacturing.Inmachiningofdieandmold,ittakesalongtimetofinishthecurvedsurface.Thereforeefficientmachiningandfinishingtechniquesaredesired.Recentlygrindingcenters(GC)aredevelopedforgrindingofvarioustypesofmachineparts.GCissuitableforfreesurfacegrindingandfinishingofdieandmoldwithelasticballtypewhee1.Freesurfacegrindingisdifficultwithmanyproblemstobesolved.Forexample,itisdifficulttodecidethegrindingconditionsforcurvedsurfacehavingvariousradiiofcurvature.Alsoitisdifficulttodecidethetoolpassaddingtheselectionofasuitablewhee1.Forthisreason,studiesoffreesurfacegrindingarerare.AbasicstudyoffreesurfacegrindingwithaballtypewheelisconductedandnewtechniquesforpolishingfreesurfacebyGCdevelopedwithelasticballtypewhee1.2ConceptofNewPolishingTechniqueUsuallyfreesurfaceofdieandmoldismachinedwithbal1endmillwithamachiningcenter(MC).Onamachinedsurface,cuspheightisproducedduetopickfeedofballendmil1.Inapolishingprocess,itisimportanttoremovethiscuspheightwithoutdecreasingmachinedformaccuracy.Themainpointsofthisnewpolishingtechniqueareasfollows:(1)Polishingisconductedwiththesamemachinetoolusedinthecuttingprocess;(2)Elasticballtypewheelisusedinpolishing,whichisexchangedbyautomatictoolchanger(ATC);(3)Inpolishingprocess,thesamecuttinglocus(CL)asusedinthecuttingprocessisappliedeffectively;(4)Astheelasticwheelisincontactwithwidearea,itispossibletotakelargeamountofpickfeed;(5)Inthepolishingprocess,onlycuspheightisremovedinordertokeepformaccuracyproducedinthecuttingprocesswithballendmill.Theserequirementswillleadtoahighproductivepolishingprocessandachieveautomaticpolishing.Tomakethistechniquesuccessfulthebasicpolishingprocessmustbeunderstoodandoptimalpolishingconditionselected,whichdoesnotdecreasetheformaccuracygeneratedinthecuttingprocess.Togetthepolishingcharacteristics,manybasicexperimentswerecarriedout.3PolishingCharacteristicsofAnEelasticBallTypeWheelDependingonthePrestonsexperience,itisknownthattheamountofremovalinapolishingprocessisinproportiontothepolishingpressureandspeed.Inordertoknowthepolishingcharacteristicsofelasticballtypewheel,basicexperimentswereconducted.Theexperimentalsetupandconditionsareshowninthispaper.Aperipheralspeedofballtypewheelchangesdependingontheactingpositionduetoitsdifferentrotationalradius.Theactingpositionisrepresentedwithanangle.PolishingexperimentswereconductedunderdifferentpolishingconditionsbychangingsettingdepthofcutcontactinganglefeedrateandYoungsmodulusofelasticwheelontheinclinedfiatsurfaceshowstherelationbetweenactualandsettingdepthofcutfor=30.Itisknownthattheactualdepthofcut,isverysmallcomparedwiththesettingdepthofcut.Also,theactualdepthofcutdosenotincreaseforsettingdepthofcutlagerthan10um.Thereasonisthatthecontactingpressuredoesnotincreaseduetotheincreaseofcontactingareabyelasticdeformationshowtheincreaseofcontactingwidthandnumberofcontactcusps.ThisisacharacteristicphenomenonforelasticwheelhavingsmallYoungsmodulus.Itisrecognizedthatroughnessofthecoarsesurfacegeneratedinthecuttingprocessisimprovedbypolishingandonlycuspheightisremovedinpolishingwithoutdecreaseofformaccuracy.Polishingparameterswereobtainedexperimentallybychangingthepolishingspeedfeedratecontactingpressure.4SimulationAnalysisofPolishedSurfaceTodevelopthispolishingmethodintovarioustypesofworkpieces,itisnecessarytoestimatethepolishedsurfaceinsimulations.Usingapolishingparameter,theremovalamountcanbeobtainedandpolishedsurfacecanbeestimated.Anelasticballtypewheelcontactswithamachinedsurfacethathastriangularcuspsgeneratedbycutting.Thepressuredistributionatthecontactingareaisobtainedwiththefiniteelementmethod.Gettingthepolishingparameterfrompolishingconditions,theamountofremovalshowsaflowchartofestimation.Anestimatedandactualsurfaceprofileofpolishedsurfacearepresentedshowinggoodagreement.Althoughtherearesomedifferences,similarvaluesandtendencyarerecognized.Fromthisresultitisconcludedthatpolishedsurfaceprofilecanbeestimatedwithsimulationmethod.